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:

4.2 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.

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 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.
Figure 4-1: Basic VCB Distribution Substation (P/E) with 1 incoming feeder, 1 outgoing feeder, 1 LV
transformer feeder, 1 MV customer
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.
Figure 4-3: Typical switching station single line diagram

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.

 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

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
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

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.

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.
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

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.

Table 4-2: Standard sizes of 11/0.4 kV indoor substations (without Metering Room)
Table 4-3: Standard sizes of 11/0.4 kV indoor substations (with Metering Room)

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.
Figure 4-7: Indoor – attached, double chamber with RCB and RTU panels (SCADA ready)
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.

4.2.2.3. 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.

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 .

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;

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.
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.

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.
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.

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

4.2.4.1.2. 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.

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:
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.
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.
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.
 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.

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:

(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.

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.

 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.

 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.

4.2.4.3.2. 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

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 2.5 mm2 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.

 Connections between meter and CT will use 2.5 mm2, PVC/SWA/PVC, 12-core, copper multi-core
armoured cables.
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.

 Connections between meter and CT will use 2.5 mm2 or 4.0 mm2, 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.

4.2.4.3.6. 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.
 Connections between meter and CT will use 2.5 or 4.0 mm2, 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.

Calculations of the maximum allowable distance between metering CT and metering cubicle can be
found in Appendix A.

 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.

Copper strip

60mm

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.

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.

 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.

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:
 As a switching station

 To give bulk supply to 11 kV customers

 To give LV supply via 11/0.433 kV distribution transformer

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.
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.