No. 3, 19 Sayyad Shirazi St, Mashhad, Iran.
051-38824146
Persian
Behso Niro Shargh company
1- High Voltage Substation Design
These substations usually operate at voltage levels of 63 kV and above ( 132 kV, 230 kV, 400 kV) and play the role of connecting power plants and transmission networks.
Main Objectives:
These substations increase the power plant's electricity, which is generally 24 kV, to high voltages, such as 400 kV, with the aim of reducing energy losses along the transmission lines, and finally reduce it to voltages of either 132 kV or 63 kV.
These substations usually operate at voltage levels of 63 kV and above ( 132 kV, 230 kV, 400 kV) and play the role of connecting power plants and transmission networks.
Main Objectives:
These substations increase the power plant's electricity, which is generally 24 kV, to high voltages, such as 400 kV, with the aim of reducing energy losses along the transmission lines, and finally reduce it to voltages of either 132 kV or 63 kV.
Key Components:
Power Transformers: the largest and most critical component.
Circuit Breaker: to interrupt current under both normal and fault conditions.
Disconnector / Isolator: to isolate equipment for service and maintenance.
Instrument Transformers (CT & VT): for sampling current and voltage for protection and measurement purposes.
Earthing Grid: extremely critical for the safety of personnel and equipment.
Protection and Control System (Relays, SCADA): the intelligent brain of the substation.
Busbar System: the main electrical connection artery between equipment.
Insulators: for supporting and insulating conductors.
Design Methods:
Layout:
Choosing between Open Air (Outdoor) Substations or Gas-Insulated Switchgear (GIS).
Open-air substations require a large area but have a lower initial cost. GIS substations are compact, suitable for urban areas and areas with high pollution, but have a very high initial cost.
Technical Studies:
Conducting detailed studies to determine equipment specifications:
Short-Circuit Level calculation.
Load Current calculation.
Equipment selection based on standards (IEC, IEEE, ISIRI).
Insulation Coordination study.
Grounding Study.
Arc Flash Study.
Software Used:
ETAP: the undisputed leader for power system analysis (Load Flow, Short-Circuit, Protection Coordination, Arc Flash).
CDEGS (or SES AutoGround): specialized software and the industry standard for designing and analyzing grounding systems.
PLS-CADD / Tower: for designing the route of incoming and outgoing transmission lines to the substation and tower placement.
AutoCAD Civil 3D: for designing topographic maps, substation siting, and earthwork operations.
AutoCAD Electrical or MicroStation: for drawing Single Line Diagrams (SLD), wiring diagrams, and equipment layout plans.
BIM Software (such as Revit): for Building Information Modeling and creating an intelligent 3D model of the entire substation (especially in large and modern projects).
2. Medium Voltage (MV) Substation Design
A medium-voltage substation is an electrical station that reduces electrical voltage from high-voltage levels (63 KV or 132 kV) to medium-voltage levels (usually 20KV or 33 kV).
Primary Objectives:
Distributing power within an area (neighborhood, industrial estate).
Reducing voltage to the final consumption level.
Key Components:
Distribution Transformer (Dry-Type or Oil-Filled)
Medium Voltage Switchgear: including circuit breakers (VCB, SF6) or Load Break Switches with fuses.
Low Voltage (LV) Panel: including Air Circuit Breakers (ACB), Molded Case Circuit Breakers (MCCB), and measurement equipment.
Protection System (Relays).
Metering System (for delivering energy to large customers).
Design Methods:
Selecting Substation Type: pole-mounted (on a pole), ground-mounted (in a concrete or metal enclosure), or indoor substation.
Load Calculation: collecting the total customer load and forecasting future growth to select the transformer rating.
Short-Circuit Calculation: for selecting MV and LV switchgear.
Protection Coordination: setting relays and fuses so that only the faulty section of the network is isolated.
Software Used:
ETAP or DigSILENT: for Load Flow, Short-Circuit, and protection coordination analysis.
AutoCAD: for drawing technical diagrams and layouts.
Specific Switchgear Manufacturers' Software : for designing, analyzing, and selecting switchgear equipment based on the manufacturer's catalog.
3. Low Voltage (LV) Substation Design
These substations are actually the final distribution boards in buildings, factories, and commercial centers that deliver electricity to the final consumer (socket, lighting, motor). In simple terms, a low-voltage substation is a place where high-voltage electricity (for example, 20 KV or 33 kV) is converted into low-voltage electricity usable by final consumers (usually 400/230 volts) after passing through a transformer.
Primary Objectives:
Final distribution and protection of consumer circuits.
Controlling lighting and motors.
Key Components:
Main circuit bbreaker.
Circuit Breakers and Fuses (MCCB, MCB).
Lighting contactors.
Timers and thermostats.
Variable Frequency Drives (VFD) for motor speed control.
Design Methods:
Load Grouping: categorizing loads based on type (socket, lighting, motor) and phase (balancing the load evenly between phases).
Cable Cross-Section Calculation: based on load current and permissible voltage drop.
Selection of Protective Devices: based on load current and short-circuit current.
Compliance with Wiring Standards (such as NEC or IEC 60364).
Software Used:
AutoCAD Electrical: very popular for designing schematics and panel layouts, and for auto-generating reports.
EPLAN Electric P8: a professional and very powerful software for designing LV panels, with project management capabilities and integration with PLC software.
Dialux or Relux: for designing and calculating lighting systems.
Simplified Calculation Software : for quick selection of protective devices and cables.
Final Summary and Overall Design Process
The design process for all levels typically follows these stages:
Preliminary Study and Data Collection: gathering load data, power source information, and environmental conditions.
Preparation of Single Line Diagram (SLD): determining the substation configuration (Busbar arrangement) and equipment.
Performing Technical Studies: load Flow, Short-Circuit, Protection Coordination.
Equipment Selection: based on the study results.
Detailed Design: layout drawings, wiring diagrams, grounding and foundation drawings.
Preparation of Protection and Control Diagrams
Preparation of Bill of Materials (BOM)
Construction and Erection Supervision
Testing and Commissioning.
Versatile and Commonly Used Software at all levels:
MS Excel: for preliminary calculations, lists, and reporting.
AutoCAD: for drawing all types of diagrams.
The choice of method and software depends on factors such as voltage level, project size, budget, local standards, and the client's preference
Power Transformers: the largest and most critical component.
Circuit Breaker: to interrupt current under both normal and fault conditions.
Disconnector / Isolator: to isolate equipment for service and maintenance.
Instrument Transformers (CT & VT): for sampling current and voltage for protection and measurement purposes.
Earthing Grid: extremely critical for the safety of personnel and equipment.
Protection and Control System (Relays, SCADA): the intelligent brain of the substation.
Busbar System: the main electrical connection artery between equipment.
Insulators: for supporting and insulating conductors.
Design Methods:
Layout:
Choosing between Open Air (Outdoor) Substations or Gas-Insulated Switchgear (GIS).
Open-air substations require a large area but have a lower initial cost. GIS substations are compact, suitable for urban areas and areas with high pollution, but have a very high initial cost.
Technical Studies:
Conducting detailed studies to determine equipment specifications:
Short-Circuit Level calculation.
Load Current calculation.
Equipment selection based on standards (IEC, IEEE, ISIRI).
Insulation Coordination study.
Grounding Study.
Arc Flash Study.
Software Used:
ETAP: the undisputed leader for power system analysis (Load Flow, Short-Circuit, Protection Coordination, Arc Flash).
CDEGS (or SES AutoGround): specialized software and the industry standard for designing and analyzing grounding systems.
PLS-CADD / Tower: for designing the route of incoming and outgoing transmission lines to the substation and tower placement.
AutoCAD Civil 3D: for designing topographic maps, substation siting, and earthwork operations.
AutoCAD Electrical or MicroStation: for drawing Single Line Diagrams (SLD), wiring diagrams, and equipment layout plans.
BIM Software (such as Revit): for Building Information Modeling and creating an intelligent 3D model of the entire substation (especially in large and modern projects).
2. Medium Voltage (MV) Substation Design
A medium-voltage substation is an electrical station that reduces electrical voltage from high-voltage levels (63 KV or 132 kV) to medium-voltage levels (usually 20KV or 33 kV).
Primary Objectives:
Distributing power within an area (neighborhood, industrial estate).
Reducing voltage to the final consumption level.
Key Components:
Distribution Transformer (Dry-Type or Oil-Filled)
Medium Voltage Switchgear: including circuit breakers (VCB, SF6) or Load Break Switches with fuses.
Low Voltage (LV) Panel: including Air Circuit Breakers (ACB), Molded Case Circuit Breakers (MCCB), and measurement equipment.
Protection System (Relays).
Metering System (for delivering energy to large customers).
Design Methods:
Selecting Substation Type: pole-mounted (on a pole), ground-mounted (in a concrete or metal enclosure), or indoor substation.
Load Calculation: collecting the total customer load and forecasting future growth to select the transformer rating.
Short-Circuit Calculation: for selecting MV and LV switchgear.
Protection Coordination: setting relays and fuses so that only the faulty section of the network is isolated.
Software Used:
ETAP or DigSILENT: for Load Flow, Short-Circuit, and protection coordination analysis.
AutoCAD: for drawing technical diagrams and layouts.
Specific Switchgear Manufacturers' Software : for designing, analyzing, and selecting switchgear equipment based on the manufacturer's catalog.
3. Low Voltage (LV) Substation Design
These substations are actually the final distribution boards in buildings, factories, and commercial centers that deliver electricity to the final consumer (socket, lighting, motor). In simple terms, a low-voltage substation is a place where high-voltage electricity (for example, 20 KV or 33 kV) is converted into low-voltage electricity usable by final consumers (usually 400/230 volts) after passing through a transformer.
Primary Objectives:
Final distribution and protection of consumer circuits.
Controlling lighting and motors.
Key Components:
Main circuit bbreaker.
Circuit Breakers and Fuses (MCCB, MCB).
Lighting contactors.
Timers and thermostats.
Variable Frequency Drives (VFD) for motor speed control.
Design Methods:
Load Grouping: categorizing loads based on type (socket, lighting, motor) and phase (balancing the load evenly between phases).
Cable Cross-Section Calculation: based on load current and permissible voltage drop.
Selection of Protective Devices: based on load current and short-circuit current.
Compliance with Wiring Standards (such as NEC or IEC 60364).
Software Used:
AutoCAD Electrical: very popular for designing schematics and panel layouts, and for auto-generating reports.
EPLAN Electric P8: a professional and very powerful software for designing LV panels, with project management capabilities and integration with PLC software.
Dialux or Relux: for designing and calculating lighting systems.
Simplified Calculation Software : for quick selection of protective devices and cables.
Final Summary and Overall Design Process
The design process for all levels typically follows these stages:
Preliminary Study and Data Collection: gathering load data, power source information, and environmental conditions.
Preparation of Single Line Diagram (SLD): determining the substation configuration (Busbar arrangement) and equipment.
Performing Technical Studies: load Flow, Short-Circuit, Protection Coordination.
Equipment Selection: based on the study results.
Detailed Design: layout drawings, wiring diagrams, grounding and foundation drawings.
Preparation of Protection and Control Diagrams
Preparation of Bill of Materials (BOM)
Construction and Erection Supervision
Testing and Commissioning.
Versatile and Commonly Used Software at all levels:
MS Excel: for preliminary calculations, lists, and reporting.
AutoCAD: for drawing all types of diagrams.
The choice of method and software depends on factors such as voltage level, project size, budget, local standards, and the client's preference