NORTH MAHARASHTRA UNIVERSITY

JALGAON

A
SEMINAR REPORT
ON

COMPACT SUBSTATION
UNDER THE GUIDENCE OF

Prof. Mr. S.C.TEMBHEKAR

SUBMITTED BY

Mr. SONAR SUMIT RAVINDRA

For
DEPARTMENT OF ELECTRICAL ENGGINEERING

P.S.G.V.P. MANDALS
D. N. PATEL COLLEGE OF ENGINEERING,
SHAHADA, DIST. NANDURBAR
[M.S.]-425409
(2015-2016)
1

NORTH MAHARASHTRA UNIVERSITY,

JALGAON

CERTIFICATE
This is to certify that, the Seminar on

COMPACT SUBSTATION
HAS BEEN SATISFACTORILY SUBMITTED BY

MR.SONAR SUMIT RAVINDRA

As a part of syllabus of
NORTH MAHARASHTRA UNIVERSITY, JALGAON
For the partial fulfillment of
THIRD YEAR ENGINEERING IN ELECTRICAL

P.S.G.V.P. MANDALS
D. N. PATEL COLLEGE OF ENGINEERING,
SHAHADA, DIST.NANDURBAR.
(2015-2016)

SEMINAR GUIDE
Prof. Mr. S.C.TEMBHEKAR

H.O.D.
Prof. Smt.K.A.Patel

PRINCIPAL
Mr. P.D.PATIL
2

ACKNOWLEDGEMENT
Every orientation work has imprint of many people and this work
is no different.This work gives me an opportunity to express deep
gratitude for the same. While preparing seminar report received endless
help from number of people.This report would be incomplete if I dont
convey my sincere thanks to all those who were involved.
First and foremost I would like to thank my respected guide
Prof. K. R. Ghadge (seminar guide) & Prof. M. G. Unde (H.O.D)
for giving me an opportunity to present this seminar and his
indispensable support, priceless suggestions and valuable time.Finally, I
wish to thanks my friends and my family for being supportive of me,
without whom this seminar would not have seen the light of day.
Every work is an outcome of full-proof planning, continuous hard
work and Organized effort.This work is a combination of all the three
put together sincerely.
Mr. Mitkari Vijay M.
T.E. Electrical Engineering
.

INDEX
1)

List of Figures

2)

Abstract

3)

Chapter 1 Introduction
a) Necessity
b) Objectives

4)

5)

Chapter 2 Description
2.1

Compactness

2.2

Current situation

2.3

Compactness improvement

2.4

M.V. Network Switches

2.5

M.V. Connection Systems

2.6

L.V. Connection Systems

Chapter 3 Construction & Safety

3.1

Design and structural features

3.2

Electrical Features & rooms

6)

Chapter 4 Moving, Maintenance & Transportation

7)

Chapter 5 Design
5.1

Building

5.2

Base, frame foundation

8)

Chapter 6 Safety

9)

Chapter 7 Case study

7.1

Technical Data

7.2

Features

10)

Chapter 8 Advantages & Applications

11)

Chapter 9 Conclusion

12)

References
4

LIST OF FIGURES
Fig 2.1 Compactness
Fig 2.2 Typical Substation Design
Fig 2.3 Footprint of typical 630 KVA Substation
Fig 2.4 Proposed substation design
Fig 2.5 Footprint of typical 630 KVA Substation
Fig 3.1 Wall insulated factory production panels
Fig 3.2 Compact substation base
Fig 3.3 Compact substation roof
Fig 3.4 Compact substation door
Fig 3.5 Compact substation ventilation louvers
Fig 3.6 M.V. Switchgear room
Fig 3.7 Transformer room
Fig 3.8 L.V. Switchgear room
Fig 3.9 Battery room
Fig 3.10 Roof & Doors
Fig 4.1 Transportation of compact substation
Fig 6.1 Compact substation with SF6- insulated RMU 8DJ20

ABSTRACT
The aim of this topic is
-To make development in MV/LV substations (indoor, outdoor and underground
substations)
- To design substation which is compact, cost-effective and have many advantages over
conventional substation.
Compact Modular Substation is based on an alternative substation economic design
concept. The total project cost is brought down to the minimum while all benefits of
conventional substation remain intact. Thanks to the state-of-the-art compact switchgear
design, a circuit breaker, disconnecting/earthing switches and measuring current/voltage
transformers can be integrated as one single unit resulting in much less installation spaces
required.
Moreover, control & protection panels, medium voltage switchgears, AC/DC
distribution boards, station battery, SCADA and optional security and condition-based
monitoring system are installed within mobile steel containers prefabricated and fully
tested in the factory. Thus, these modules are ready for easy system integration in the
plug-and-play fashion at site.

Chapter-1
1.1 INTRODUCTION
Compact substations are defined as Substations with type tested equipment
comprising distribution transformer, medium

voltage switchgear, low voltage

switchboard, connections and associated equipment in enclosed unit.

The recent liberalisation of the electricity supply industry in Europe has led
utilities to think thoroughly about how to optimise MV/LV substations for reducing
global costs.
In Spain the conclusion of optimisation has been:
a) Cost: analysing how to reduce global costs (equipment, manpower, space, losses,
maintenance)
b) Ensuring the continuity of electrical supply:
Single transformer (protected by fuses)
Substations in a ring MV network (two feeders).
Consequences are:
a) To shorten low-voltage networks in order to reduce LV losses, so the MV/LV
substation is closer to the customers load.
b) Power transformer reduction: maximum 630 KVA up to 24kV or 36kV.
c) Space reduction (surface is expensive): dimension optimisation.
d) Compact solutions: turnkey solutions.

1.2 NECESSITY
1. Ordinary substation requires more space because its auxiliaries also big but
compact substation needs less space as it has compact auxiliaries.
2. In Ordinary Substation Not simplified planning for overall project.
3. In Ordinary Substation, Fault chances are more. But in case of compact
substation, fault chances are less.
4. Ordinary Substation is suitable only for outdoor. While, Compact substation
suitable for both indoor and outdoor.
5. Compact substation reduces civil work and installation time also.
6. In compact substation, Simple logistics and low transport costs, Reduces
installation and wiring work on site, Simple and quick installation and

commissioning on site, Optimized lead time and Mitigation of risks due to

delays and errors
7. In compact substation, reduced project duration and costs, Simplified planning
for overall project.

1.3 OBJECTIVES
The aim of this seminar is design of compact substation. This work is expected to
understand the necessity and advantages of compact substation. Here we made the
compact substation which is very usefull in hilly and inaccessible area.
The objectives of this topic is
1. To reduce the cost of substation installation.
2. To make mobile substation unit for power requirement i.e.for short
duration or long duration.
3. To reduce the cost of space required.
4. To increase overall efficiency of substation.

Chapter- 2
LITERARTURE SURVEY
2.1 COMPACTNESS
The compact substation is a global solution with three compartments (MV
switchgear, transformer and LV distribution board) connected directly without cable onto
a metallic chassis.
There will be three different types of compact substations:
a) Indoor compact substation: equipment with three compartments (MV switchgear,
transformer and LV distribution board) on a moving (with wheels) metallic chassis.
b) Outdoor compact substation: concrete prefabricated substation with outdoor
operation in order to reduce dimensions.
c) Underground compact substation: concrete prefabricated substation with outdoor
operation

to

reduce

dimensions

and

to

improve

exploitation

conditions.

In order to reduce more the dimensions of the substation and the footprint (outdoor
solutions) , it is effective to integrate the transformer protection and switching within the
transformer compartment.
Indeed, integrating protection and switching in the transformer enables to reduce
the size of MV switchgear; and it is clear that integrating protection and switching in the
transformer increases the height of the transformer but not its ground dimensions.With
this type of solution it is possible to design a 2.7 m (surface) kiosk up to 630 KVA
24kV.

Fig 2.1 Compactness

2.2CURRENT SITUATION
The indicator of the substation compactness is its footprint. The footprint of the
equipment is the total required surface area (in m2) that is covered by the substation

equipment. The footprint of the kiosk is the total surface area that is necessary to operate
the kiosk.
Today substations require about 1 m of free space for door access. If the kiosk has
access doors on two faces (one for MV and one for LV), the footprint requires in addition
a free way of 0.8 m to join the two faces. Moreover, it is necessary to let 0.2 to 0.5 m of
free space in front of the ventilation.
In the traditional substation design (Fig.2.2), the MV switchgear compartment is
big since it consists of two switches and one fuse-switch. Moreover, due to their large
curve radius, the MV and LV cables require to install MV switchgear, transformer and
LV switchboard with large space in between. For example, one 630 kVA substation with
an equipment footprint of 5 m2 (2m*2.5m; Fig. 2.3), with two access faces and
ventilation on the other sides requires a kiosk footprint of 13.5 m2 (3m*4.5m; Fig. 2.3).

Fig 2.2 Typical substation design

Fig 2.3 Footprint of typical 630 KVA substation

2.3 COMPACTNESS IMPROVEMENT

In order to reduce the equipments as well as the kiosks footprint, it is proposed
to integrate the protection and switching within the transformer tank (Fig. 3). Another

10

way to optimize the dimensions of the substation is to use direct connections between the
MV switchgear and the transformer as well as between the LV switchgear and the
transformer (Fig. 3)

Fig 2.4 Proposed substation design

In the proposed design, the integration of protection and switching in the transformer
enables to reduce the size of the MV switchgear and then to be able to design an
optimized kiosk in terms of dimensions with only one operating face for MV and LV
(Fig. 4). For example, one 630 kVA substation of the proposed design (Fig. 3) has an
equipment footprint of 2.72 m2 (1.6m*1.7m; Fig. 4) and requires a kiosk footprint of 5.88
m2 (2.1m*2.8m; Fig. 4). For the specific example of the 630 kVA substation, the
equipment footprint is reduced by 46% (from 5 m2 to 2.72 m2) and the kiosk footprint is
reduced by 56% (from 13.5 m2 to 5.88 m2).

Fig 2.5 Footprint of proposed 630KVA Substation

2.4 MV NETWORK SWITCHES

MV network switches comprise 2 integrated, compact functional units. This
integrally insulated self-contained assembly comprises (a) a sealed for life stainless steel

11

enclosure that includes the active parts, the disconnector and the earthing switch, (b) two
cable compartments for the MV network connection, (c) one LV compartment, and (d)
one control compartment.
MV network switches ensure safety of people due to internal arc withstand in
conformity with IEC 60298 standard, visible earthing, 3 position switch providing natural
interlocking, and reliable switch position indicators.
The performance levels obtained with MV network switches meet the definition
of sealed pressure system, in line with IEC recommendations. The disconnector and the
earthing switch offer full operating guarantees for the operator. The enclosure is filled
with SF6 at a relative pressure of 0.2 bars. Once filled, it is sealed for life. Its sealing is
systematically checked in the factory, giving a service life of 30 years. Therefore the ring
switch does not require any maintenance of its active parts. Electrical arc extinction is
achieved using the puffer technique in SF6.

2.5 MV Connection System

A direct factory-built MV connection between the MV switchgear and the
transformer enables to put them directly one against the other. In addition to the footprint
reduction, this solution can improve the reliability if the MV connection is installed in the
factory, since the MV switchgear and the transformer can be tested as a set.
In case of factory-installed, the MV connection (called block type MV
connection) comprises three bi-conical sleeves made from over-moulded elastomer on
copper braids. These assemblies provide the electrical connection between the MV
network switch and the transformer. A mechanical positioning system ensures perfect
position with each of the bushings.
In case of on-site-installed, the MV connection (called kit type MV connection)
comprises three cables which are pre-equipped with over-moulded connectors at both
ends. When installing the substation on-site, these cables are to be connected to the
transformer and to the MV network switches. A set of flanges fixes them at both ends.

2.6 LV Connection System

The connection of the transformer and the LV fusegear is achieved using a factorybuilt direct LV connection. This connection comprises a single component fixed with two
bolts.

12

The proposed LV connection system drastically reduces the distance between the
LV fusegear and the transformer. Moreover, it is easy and quick to install the LV
connection system, since no cables are needed and the fitting of the connection takes less
than five minutes.

13

Chapter-3
CONSTRUCTION AND SAFETY
3.1 DESIGN AND STRUCTURAL FEATURES
Design:-

Fig 3.1 Wall insulated factory production panels

Compact substations can be designed in accordance with requirement of project
equipment in compact substations can be provided as ex-proof.
Dimension:Dimensions of compact substations can be designed in accordance with
requirement of project and are specified in view of the fact that rooms, dimension of
switching equipment, operating conditions and operating area.
Base:-

Fig 3.2 Compact substation Base

14

Compact substations are assembled on a base. Base are made of NPU or NPI shapes
according to load on the floor and NPU & NPI shapes are covered hot dipped galvanised.
Frame:Frame of compact substation is made of 5sq.mm. ST-37 and covered with hot
dipped galvanised for long term using.
Wall & Roof:-

Fig 3.3 Compact Substation Roof

Sandwich panels are used on wall and roof. Internal wall and external wall of
sandwiched panel are covered with 100-275gr/sq.m Zinc sheet against to corrosion.
Insulating is provided with Polyurethane. Non-flammability class of panels is Euro ClassB.
Doors:-

Fig 3.4 Compact Substation Door

15

Doors are made of sandwich panels. Doors can be opened to 120 outside and
designed against to 20J mechanical shocks.
Ventilation:-

Fig 3.5 Compact substation ventilation louvers

Natural ventilation is provided by means of ventilation louvers for air intake in the
lower part of the ventilation doors or ventilation wall elements. The air is extracted at the
top of the roof. Natural air circulation ensures sufficient cooling of the transformer. The
ventilation louvers are of the labyrinth type. As standard Power IT CSS is classified and
type tested in accordance with temperature class K20. Temperature class K10 can be
achieved for all surface mounted substations by increasing the ventilation area for the
transformer room.

3.2 Electrical Features and Rooms

1. M.V. Switchgear Room :-

Fig 3.6 M.V. Switchgear rooms

16

In M.V. Switchgear room metal enclosed, metal clad and RMU can be used.
Dimensions of M.V. room are specified in accordance with equipment dimensions in
the room.
2. Transformer Room :-

Fig 3.7 Transformer Room

In transformer room, dry type and oil type transformer can be used.
Dimension of transformer room are specified in accordance with power of
transformer. M.V. Switchgear and transformer are connected with XLPE Cable
and transformer & L.V. switchgear are connected with cable or busbar in
accordance with requirement of project.
3. L.V. Switchgear Room :-

Fig 3.8 L.V. Switchgear Room

17

In L.V. Switchgear room withdrawable MCC Distribution panel, UPS, LV

Distribution panel, HVAC panel and modbus panel can be installed. Dimensions
of LV room are specified in accordance with equipment dimensions in the room.
4. Battery Room :-

Fig 3.9 Battery Room

There are Ni-Cd batteries and DC breakers in battery room.
Snow panel below door
Snow panels make it easier to open the doors after heavy snowfall. The snow
panel replaces the lower third of the door, and is secured to the wall. It can be removed
once the door is open. Normal switching operations are not blocked by the snow panel.
This option is not available to all solutions.

Door gaskets

Fig 3.10 Roof & Doors

To provide protection against dust being drawn into the medium voltage and low
voltage compartments, the doors can be fitted with gaskets that increase the protection.

18

Chapter no. 4
MOVING, MAINTENANCE AND TRANSPORTATION
MOVING:
A wooden pallet is bound underneath the substation in order to help moving and lifting
the substation. Or the compact substation is directly mounted on a automobile.
MAINTENANCE:
It is necessary to check and maintain the substation on regular basis in order to keep it in
good operating condition.
TRANSPORTATION:

Fig.4.1 Transportation of compact substation

When receiving the substation please pay attention to following matters:
-there are no transportation damages,
-delivery is complete and in accordance with the order
-sign the freight note and keep your copy of it

19

CHAPTER-5
DESIGN
5.1 Building
The building is typically divided into three rooms for the medium voltage and low
voltage switchboards and distribution transformer. The roof can be selected with either 6
or 18 slope, and is secured to the corner sections by bolts. The entire roof is detachable,
and is supported by a beam with ventilation openings.
As standard the doors are fitted with handles for padlocks and closed by means
of a two-point device, securing them to the top and base frame. The doors are fitted with
stainless steel hinges and equipped with door stoppers.
The wall and roof modules are assembled by means of a self-locking design,
hence the use of sealant is not necessary. Clinching technology is used to assemble walls,
roof and base frame. Lifting fittings, corner sections, bearing sections, base plates and
cable covers are assembled using bolts. The low voltage switchboard and the medium
voltage switchgear are bolted to the building.
Walls, roof and doors are made from 1.5 mm galvanized sheet steel. The
building is painted with a coat of Oxide wet paint. The corrosion category corresponds
to C4 H according to ISO 12944. Corrosion protection in the form of hot-dipped
galvanized base frames guarantees a long mechanical service life.

5.2 Base frame and foundation

All steel Power IT CSS are mounted on a base frame made of 2 mm galvanized
steel. Non Walk-in CSS is mounted on a concrete slab with recesses for cables to the
medium voltage and low voltage compartments. Concrete slab can also be selected for
Walk-in CSS. For the Compact type the base frame is placed on a concrete foundation
with an integrated oil collection pit. All foundations and base frames have detachable
panels in front of the medium voltage and low voltage rooms to allow the easy insertion
of cables.

20

CHAPTER-6
SAFETY
Safety of property and persons, respect for the environment and improvement of
operating conditions are gaining in importance daily. As the ultimate element in the
electricity supply chain, the distribution transformer is one of the most widespread items
of equipment and, being located nearest to the user, it is therefore one of the most
sensitive. Avoiding damage to distribution transformers is vital, otherwise continuity in
power system delivery may be seriously disrupted. Furthermore, repair or replacement is
expensive and time-consuming. Consequently, it should not come as a surprise that
transformer protection forms a subject of a permanent research effort .
In the distribution substation, the faults downstream the substation (LV network) are
eliminated by the LV fuses and they dont include any risk concerning safety. Internal arc
test in MV switchgear enables to assure safety in case of fault in this equipment.
On the other hand, in the substation transformer, current protection solutions are not able
to assure total safety. Two types of solutions are currently used:
MV fuses with strikers that are tripping the transformer switch
Current relay that is tripping the transformer circuit breaker.
Fuses are very effective for high fault current (internal arc within transformer tank)
because they limit and interrupt the current in approximately 5 ms. On the other hand, in
case of fault in the winding (short circuit between turns causing weak fault current with
gas build up), there is a risk for fuses to not act. The reason is that fuses can interrupt
currents only 8 times higher than the nominal current of the transformer, or with strikers
that are tripping the transformer switch it can be interrupted by the switch a current that is
5 times higher than the transformer nominal current. As a result, in case of weak fault
current, the transformer tank can be exploded due to the overpressure and there is a risk
for safety and pollution of the environment by oil.
Circuit breakers with current relay are more effective against weak fault current because
the threshold is generally set at 1.5 to 1.8 times the nominal current of the transformer.
However, for fault current weaker than this threshold, the risk of explosion is still present.
Moreover, for high fault current, the time necessary to interrupt this fault is
approximately 80 ms, so there is a risk of explosion of the transformer tank.
21

Degree of protection
The standard degree of protection for CSS is IP23D in accordance with EN
60529. If required, CSS can be delivered with doors of higher IP class, by including
gaskets and omitting the ventilation openings in the doors.
Protection against climate effect
The climate in substations can be extreme, due to moisture, condensation and
dirt. In coastal locations sea salt on the surface of open, insulated surfaces can cause
leaking current, which can result in flashover. It is strongly recommended that equipment
used can withstand harsh climate service conditions.
Protection against internal condensation
To avoid any condensation dripping on to the low voltage switchboard, an
additional cover can be installed over the low voltage room.

22

CHAPTER-7
CASE STUDY
Siemens has been serving the Indian market with a wide range of Medium voltage
Power Distribution Systems for more than four decades. Siemens Compact Substations
(CSS) is a product from the MV Distribution product family and is designed keeping in
mind the fast growing power needs of Indian cities, combined with reduced urban space
availability. The CSS can be ideally installed in residential and commercial complexes,
industrial environments, utilities where free space is a major constraint.

Fig 7.1 Compact substation with SF6-insulated RMU 8DJ20

23

7.1 Technical Data

Reference standard

IEC61330

Rated voltage

11kV*

Rated power frequency

Withstand voltage kV RMS, min

28kV*

Rated lightning impulse

Withstand voltage kV, 1.2/50 MS

75kV*

Rated frequency

50Hz

XMER rating

1000KVA**

Enclosure degree of protection

IP23

* Option higher voltages on request

**Option higher rating transformer on request

7.2 Features
Factory built and tested
Easy and simple to install reducing the on-site operations
Ready for network connection
Design complies to IEC 61330
Maintenance free SF6 insulated Ring Main Unit for MV networking
SCADA compatible equipments
Available with oil cooled/dry type transformers up to 1000kVA
Rust, corrosion and weather proof enclosure
Independent access for all the compartments for routine maintenance

24

CHAPTER-8

ADVANTAGES AND APPLICATION:

ADVANTAGE:
1. Pre-assembled

enclosures,

which

reduce

civil

work,

installation

and

commissioning times.
2. Different range of distribution transformer.
3. Reduction of environmental impact.
4. Reduced overall plant & project costs.
5. Significant land saving and Simplified planning for overall project.
6. Compact: can be installed in a limited space of 6 sq. Meter.
7. All live parts in the compact substation are protected against unintentional contact
by means of lockable doors.

APPLICATION:
1. For residential tower, to be installed on the top of the building, roof or in the
Basement.
2.

Can be installed in the site of factory or industrial complex.

3. Suitable for being use by companies involved in road , tunnel construction as well
as Mining project.
4. Can be use by engineering & contracting companies to accelerate their in hand
project.
5.

Can be installed in recreation and public location such as park & pavement
corner.

6. Suitable for airport & metro station.

25

CHAPTER-9

CONCLUSION:

From this seminar, we study what is Compact Substation, its necessity,

application and advantages.

We come to know that Compact Substation requires less floor space hence
it is necessary to installed it.

26

REFERENECES:

[1] P.S. Georgilakis, N.D. Doulamis, A.D. Doulamis, N.D. Hatziargyriou, and S.D.
Kollias, A novel iron loss reduction technique for distribution transformers based
on a combined genetic algorithm-neural network approach, IEEE Trans. Systems,
Man, and Cybernetics, Part C: Applications and Reviews, vol. 31, no. 1, February
2001, pp. 16-34.
[2] C. Lewiner,Business and technology trends in the global utility industries, IEEE
Power Engineering Review, vol. 21, no. 12, December 2001, pp. 7-9.
[3] R.K. Green, Twenty-first century utilities, IEEE Power Engineering Review, vol.
21, no. 12, December 2001, pp. 4-6 & 12.
[4] A. Hoover, Enabling the lean, agile, digital utility, IEEE Power Engineering
Review, vol. 21, no. 12, December 2001, pp. 13-14.
[5] M. Bidaut,MV/LV substations, developments for increased satisfaction of
requirements, in Proc. EMSO 2000 Int. Conf.

27