atkins

ATK002-422-C240-FD-E-RPT-00012 1

Saudi Binladin Group

Electrical System Design Report - Auxiliary Electrical Substations SBG/DAH Report No: June 2012

taba7756Typewritten Text422-C240-FD-E-RPT-00012-A

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Notice This document and its contents have been prepared and are intended solely for Saudi Binladin Groups information and use in relation to King Abdulaziz International Airport.

Atkins assumes no responsibility to any other party in respect of or arising out of or in connection with this document and/or its contents.

Document History

JOB NUMBER: Package 422 Atkins Internal Tracker Number: ATK002-422-C240-FD-E-RPT-00012 Revision Status Originated Checked Reviewed Authorised Date

A For DAH Review 100% Submission HNM BG MH MH 01/06/12

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Table of Contents

Contents

1.0. Abbreviation and References 5

1.1. Abbreviations 5

1.2. References 6

1.3 Client References 8

1.4 Atkins References 8

2.0 Introduction 9

3.0 The Basis of Design 10

3.1. Design Criteria 10 3.1.1. Climatic Conditions: 11 3.1.2. Site Infrastructure 11 3.1.3. Auxiliary Electrical Substations 11 3.1.4. MV Switchgear 13 3.1.5. LV Distribution Network 13 3.1.6. Metering Instruments 14 3.1.7. Control Voltages 15 3.1.8 Battery System (125 V DC Power Supply) 15 3.1.9 Raceways and Conduits 15 3.1.10.Disturbance and Interference 16 3.1.11. Outdoor Package Substation Housing 17 3.1.12. Seismic Restraints 18 3.1.13. General Purpose Power Circuits and Fixed Equipment

Supplies 18 3.1.14. Internal lighting 19 3.1.15. Lighting Control 19 3.1.16. External lighting 19 3.1.17 Emergency Lighting 19 3.1.18 Earthing and Bonding 20 3.1.19. Lightning Protection 20 3.1.20. Telecommunications and SAS Facilities 21 3.1.21. Testing 21

4.0. Mechanical Services Design 21 4.1. General Overview 21 4.1.2. External Temperatures & Conditions 22 4.1.3. Internal Temperatures & Conditions 22 4.1.4. Internal Cooling Loads 22 4.2.1. Automatic controls SCADA, SAS and BMS 22 4.2.2. Electrical Metering 23

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4.2.3. Transformers 23 4.2.4. Automatic Transfer and Static Switches 23 4.2.5. Fire Suppression 23

5.0 Power Distribution System and Equipment 24 5.1.1. Package Substation Foundation and Enclosure 24 5.1.2. Substation Layout and Dimensions 24 5.1.2.1 MV Compartments 24 5.1.2.2 Transformer Compartment 24 5.1.2.3. LVAC Compartment 25 5.1.2.4. Battery Room 26 5.1.3. Feeder Protection 26 5.1.4. Standby Supply 27 5.1.5. Outdoor Feeder Cables 27 5.1.6. Electrical Installation 27 5.1.7. Earthing Installation 29 5.1.8. Lightning Protection Installation 30 5.1.9 Estimated Maximum Demand and Transformer Rating 31 A. Appendix 32 A.1 Auxiliary Electrical Substation Drawing list 32

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1.0 Abbreviation and References

1.1. Abbreviations

A.C. - Alternating Current

ACB-Air Circuit Breaker

BMS- Building Management System

CT Current Transformer

CPC Circuit Protective Conductor

D.C.- Direct Current

DG Diesel Generator

Double Ended Double transformer substation

EMI Electromagnetic Interference

IP Ingress Protection

LSZH- Low Smoke zero halogen

LV Low Voltage

LPS Lightning Protection System

LSF Low Smoke Fume

MCB Miniature Circuit Breakers

MDB- Main Distribution Board

MCCB-Moulded Case Circuit Breaker

MV Medium Voltage

NAC- Network Access Controller

PLC- Programmable Logic Controller

RCD- Residual Current Device

SDB Sub-Distribution Board

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SCADA- Supervisory Control and Data Acquisition

SAS Special Airport Services

Single Ended Single transformer substation

VCB-Vacuum Circuit Breaker

VT Voltage Transformer

The following references are used throughout this document.

1.2. References

The electrical system shall be designed in accordance with:

BS 7671 Requirements for Electrical Installations (IEE Wiring Regulations 17th including Amendment No. 1).

NFPA: National Fire Prevention Association Codes. Chapter 10 Electrical code Chapter 70 Electrical Code Chapter 72 Fire Alarm code Chapter 780 Lightning protection code

The equipment/systems comply with all related International standards as required in the Contract. This generally includes the following standards where applicable:

NECA: Standard Practices for Good Workmanship in Electrical Construction (ANSI)

NFPA: National Fire Protection Association.

NEMA: National Electrical Manufacturers Association.

ANSI: American National Standards Institute.

IEE: Institution of Electrical Engineers.

IEEE: Institute of Electrical and Electronics Engineers.

UL: Underwriters laboratories.

BSI: British Standard Institution.

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EN: European Norm.

CIE: International Commission on Illumination.

IEC: International Electrotechnical Commission.

CIBSE: Chartered Institute of Building Services Engineers.

ISO: Standard by the International Standard Organization.

TIA/EIA: Telecommunication Industry Association / Electronic Industries Alliance.

ICAO: International Civil Aviation Organization.

FAA: Federal Aviation Administration.

ASME: The American Society of Mechanical Engineers.

GACA (General Authority of Civil Aviation Regulations)

SASO (Saudi Arabian Standards Organisation)

Standards: equipment and component parts are to comply with the following Standards:

Division 26 Section Grounding and Bonding Division 26 Section Medium Voltage Cables Division 26 Section Busway Division 23 Connections to BMS System, including interface elements. IEC 62271: Common clauses for MV switchgear and control gear standards IEC 62271-200: A.C. metal-enclosed switchgear and control gear for rated voltages above

1 kV and up to and including 52 kV

IEC 62271 : MV switchgear and control gear standards IEC 62271-200: A.C. metal-enclosed switchgear and control gear for rated voltages above

1 kV and up to and including 52 kV IEC 62271 : MV A.C. circuit breakers IEC 60071-1 : Insulation coordination IEC 62271 : MV A.C. fuse-switch combinations and fuse-circuit-breaker combinations IEC 62271 : A.C. disconnectors (isolators) and earthing switches IEC 60265 : MV switches IEC 60099 :Surge arrestors IEC 60044 -1 :Metering and protective current transformers (CTs) IEC 60044-2 :Metering and protective voltage transformers (VTs) IEC 61260 :Relays: IEC 60051 :Reading instruments IEC 60051 :Watt-hour meters IEC 60076 :Power transformers: IEC 60296 :Insulating oil IEC 60376 :Sulfur hexa-fluoride IEC 60282 -1 :Fuses IEC60502 & BS6387 :LV Cables 600/1000V Single core cable

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1.3 Client References

Section 261116 - Outdoor Package Substation Specification, dated July 2011

1.4 Atkins References

ATK002-000-A000-FD-M-RPT-00001 BMS Design Report

ATK002-000-C100-DF-E-RPT-0003 SCADA Design Report

ATK002-422-C240-FD-E-RPT-0010 Grounding General Requirements

ATK002-422-C240-FD-E-RPT-0009 MV Electrical Distribution Protection

ATK002-422-A000-FD-Y-RPT-0001 - DDR SAS ICT Communication Pathways ATK002-422-A000-FD-Y-RPT-0003 - DDR SAS ICT Communications Backbone Cabling ATK002-422-A000-FD-Y-RPT-0004 - DDR SAS ICT Communications Horizontal Cabling ATK002-422-A000-FD-Y-RPT-0005 - DDR SAS ICT Grounding & Bonding for

Communications Systems ATK002-422-A000-FD-Y-RPT-0006 - DDR SAS ICT Communications Systems

Identification ATK002-422-A000-FD-Y-RPT-0010 - DDR SAS ICT Computing and Storage System ATK002-422-A000-FD-Y-RPT-0011 - DDR SAS ICT Access Control System ATK002-422-A000-FD-Y-RPT-0012 - DDR SAS ICT Video Surveillance System ATK002-422-A000-FD-Y-RPT-0013 - DDR SAS ICT Security Access Detection ATK002-422-A000-FD-Y-RPT-0031 - DDR SAS ICT Fire Alarm System

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2.0 Introduction

The King Abdul-Aziz International Airport (KAIA) is expanding its runway and passenger capability. To facilitate this expansion, a new Air Traffic Control tower, a new Passenger Terminal, Transport Facilities and supporting buildings will be constructed. The new airport will be constructed in three phases.

Phase 1 will support up to 30 million passengers per year.

Phase 2 will allow the capacity to grow to 45 million. This is provided by an additional passenger terminal building (PTB2).

Ultimate Phase 3 will have a capacity of 80 million passengers per year. This is

provided by the additional passenger terminal building (PTB3). The purpose of this document is to define the design principles and criteria of the proposed Outdoor Package Substation Auxiliary Electrical Substations for the expansion of the King Abdul-Aziz International Airport in Jeddah. The basis for the design proposal is covered in this report. This report contains the electrical design criteria of the Auxiliary Electrical Substations and the basic design requirement for the electrical equipment/system. The Substations are required provide LV supply to various facilities being constructed under contracts 422. The Electrical and Building Services designs and installations shall generally conform to normally accepted design criteria, standards and regulations as identified within this document. The Outdoor Package Substations are provided with dual (A and B) 13.8kV incoming supply from the Airport Load Centres. A single ended package substation combines a single power transformer, MV switchgear and LV distribution board in a single transportable unit ready for operational on being fixed position on prepared concrete foundation (SLAB) and connected to the airport load centre. A double ended substation combines two transformers, two MV switchgears and a LV distribution board. Auxiliary Electrical Substation 1, 2, 3, 4, 5, 7 & 8 will be double ended substations. Auxiliary Electrical Substation 6 will be single ended substation. The document has been produced on information gained from the Outdoor Package Substation Specification 261116, dated July 2011. Please refer to associated design guides below and the associated outdoor substation drawings list in Appendix A.

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3.0 The Basis of Design

This document has been compiled to be a central reference for the basis of design for the entire Electrical System requirement for Auxiliary Electrical substations facilities within the 422 packages of the overall project. It should be noted that the client, Saudi Bin Laden Group (SBG), tendered and were awarded this project on the basis of contract documentation. Contractor to abide by the Tender Number, J-1X-422-PF-0, Exhibit D Special Specifications, Part D1 and Tender Number, J-1X-422-PF-0, Exhibit D Special Specifications, Part D2 for the design of the equipment/system covered in this report.

3.1. Design Criteria

The Total Normal and Emergency maximum electrical power demand loads of each Outdoor package substation shall be provided in the Appendices and the calculated transformer rating. The contractor should verify the normal and emergency loads during final construction.

The Project requires both single ended and double ended package substations, where the MV switchgears are fed by 13.8kV dual radial feeders from the utilities distribution Network coming from the respective load centres.

Outdoor unit substations shall be designed to IEC Standards.

All outdoor substations shall have three separate compartments to accommodate MV switchgear, Transformer, and LVAC switchgear. A separate battery room with air-conditioning shall also be provided for the single ended substation.

The Layout of the plant within the outdoor substation is based on the clearance and spacing requirements constraints applied on this project.

Transformers shall be of oil type design with suitable oil bund to be designed by the contractor. The transformers shall be designed for 100% capacity where double ended configuration is applied so one transformer can assume the total load in the event of a single transformer failure, including 30% spare capacity.

Outdoor Substations components electrical/mechanical services shall interface through the BMS panel, Comms Panel, NAC Panel for control and monitoring (locally/remotely) through the BMS SCADA panel.

The Contractor shall source Equipment and plant based on the KAIA project approved list of suppliers.

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3.1.1. Climatic Conditions: The general design criteria are listed below. The equipment shall be designed for the following climatic conditions: Location Jeddah, Saudi Arabia Design Ambient temperature 45 Deg C Altitude 2 to 6 M above mean sea level Rainfall 50 mm Relative Humidity 3 to 100 % Pollution level III Heavy, 25mm/kV Wind speed 93 kph

3.1.2. Site Infrastructure Two incoming MV supplies (A & B) shall be provided to the substations by the respective Load Centres. These will be terminated in the MV switchgear required for each of the outdoor package substations, via floor mounted, circuit breaker panels. The incoming MV supplies A and B to the package substation shall be in a concrete duct bank. The A and B concrete duct bank shall align with the substation foundation slab MV cable duct entry point. The substation foundation slab shall have a trench which will be 1 metre deep and wide for outgoing LVAC cables on both side of the LVAC switchroom. Each side shall have a sixteen (4 x 4) 100mm OD duct arrangement for outgoing LVAC cables. The LVAC switchroom shall also house the communication equipment. The communication cables either fibre optic or metallic shall also have a separate communication cable duct entry to the package substation.

3.1.3. Auxiliary Electrical Substations

Auxiliary Electrical Substations (AES) shall provide supply to various, pump stations, low voltage valves and tunnel lighting installed on site, 8 (AE1 to AE8) Auxiliary Electrical Substations have been designed.

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Normal Power Supply: Normal power supply will be arranged through SEC (Saudi Electric Company) supply at 13.8kV to the load centre. Power supply at 13.8kV level from load centre is distributed in the airport and is further stepped down to Low Voltage 400V power supply to meet the requirements for various facilities.

Emergency Power Supply Emergency power supply is secured from the central diesel MV generators located in the Load Centre normally supplying the Auxiliary Electrical Substations. Local LV DG set shall not be provided for the Auxiliary Electrical Substations. Upon failure of normal utility supply, central generators shall operate and provide essential supply to the essential loads (breakers controlled by the SCADA system) and once the normal conditions are restored, the load shall be transferred back to normal power supply. LV Cable Sizing and Protection Coordination Studies Local feeders and branch circuits are sized for a total maximum volt drop of 5% of the nominal voltage from the point of supply during running condition as per requirements; typically 3% for feeders and 2% for branch circuits. All settings and CB ratings are indicative and need to be verified as part of a LV protection coordination study relevant to each package substation. The LVAC cable feeder size, relay settings and LV Protection coordination studies shall be detailed in a separate report. Outdoor feeder MV and LV cables (including communications cables) are to be run in concrete enchased duct banks. No direct buried cables are to be used. Spare Capacity: A spare capacity of 30% shall be considered for equipment sizing (e.g. transformer, etc)

30% spare breakers are provided in the distribution levels starting from the main LV switchboard (MDB), sub distribution boards SDB, etc.

MV - bulk supply 13,800 Volt 60Hz, three phase, 3 wire and Earth

(Earth cable shall be installed in a separate duct) LV - general supply 400 Volts + 10% -6% - 60Hz, three phase, 4 wire

230 Volts + 10% - 6% - 60Hz, single phase, 2 wire LV earthing system type TN-S MV Neutral Resistive Earth LV Neutral Solidly Earthed

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3.1.4. MV Switchgear

The MV Switchgear shall comprise of two electrically interlocked, arc resistant, vacuum circuit breakers (VCBs) of the withdrawable type. The Circuit breaker shall be floor mounted with bottom entry incoming cables. The MV circuit breakers shall be monitored and controlled locally/remotely from the SCADA Panel via the BMS System. The interconnection between the MV switchgear and the Transformer shall be via a MV power cable of XLPE insulation (to be provided by contractor). In the event of loss of supply on one feeder (A or B) the MV Switchgear will changeover to re-supply the transformer from the other circuit. In the event of loss of supply for both the A and B feeders the generation at load centres shall start and commence to re-supply the essential loads under the control of BMS System.

3.1.5. LV Distribution Network Transformers of rating 13.8 kV / 420V oil type transformers (Transformer TR1 & TR2) located either end of the double ended package substation. These transformers shall feed dedicated LV main switchboards (MDB1 & MDB2). The connection from the transformer LV to the incoming LV breaker on the LVAC board shall be via a busduct arrangement. The switchboards shall contain incoming air circuit breakers (ACBs) and combination of ACBs and moulded case circuit breakers (MCCBs) outgoing feeders. LV compartment busbar assembly shall comprise of fully insulated set of 3- phase and neutral copper busbars. Neutral shall to be fully rated. Earth bar shall be provided at lower end of compartment. Both transformers are normally on line feeding separate sections of the Main Distribution board MDB1 & MDB2, joined via an automatic bus coupler. This enables the load on one transformer to be transferred to the other transformer in the event of a failure of a transformer or for routine maintenance. Loss of MV supply to one transformer can also result in a LV bus transfer. One transformer shall feed one MDB in the single ended substation. In the event of transformer failure or routine maintenance the supply shall not be maintained. LV Compartment Construction shall be of dead front type, consisting of main circuit breaker, busbars, outgoing circuit breakers, as required, instrumentation and accessories. One section of the LVAC switchboard MDB1 is designated Essential and the other MDB2 is designated non essential. The essential switchboard is supported by stand-by generators from the associated Load Centre.

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Low voltage supplies from the essential and non essential sections of each switchboard shall be run to the various external loads located outside the package substation and also internal load requirements of the package substation. The Sub-distribution board (SDB) maximum number of outgoing ways shall be 14. The LVAC Board automation shall be achieved via PLC panel mounted to either end for the LV feeder panels to control and monitor the whole LVAC switchboard through interface with the SCADA Panel. LVAC Board PLC designed around IEC 60870-5-101 is a standard for power system monitoring, control & associated communications for telecontrol, teleprotection, and associated telecommunications for electric power systems. The LVAC PLC shall interface with LV breakers, including interface elements such as relays, transducers, etc. as specified and /or as required. The main incoming and outgoing circuit breakers of the main distribution board shall be monitored and controlled locally/remotely from the BMS system. Circuit breakers 800A and above shall be withdrawable ACBs (3 pole type for outgoing feeders or 4 pole type for incomers and bus-section). LV Cables shall be XLPE Single core only and shall be specified in mm square. Transient Voltage Surge Suppression TVSS devices are to be provided in compliance with Section 264313. Low voltage supply outlets at 230 Volts, 60 Hz, shall be installed within each compartment of the substation. The LV compartment main circuit breaker shall have solid state trip unit with long-time, short time and ground-fault pick up and time- delay adjustments and with high instantaneous over-current trip, to correspond with transformer rating and LV interrupting capacity at location. This shall be time and current coordinated with MV protection on primary side circuit breakers and protective devices downstream as required shall be provided in a separate report as mentioned previously.

3.1.6. Metering Instruments

Multifunction meters on all main incoming feeders shall be linked to SCADA for Analogue voltmeters, ammeters and indication lights on each incoming phase. LVAC board compartment instrumentation shall include voltmeter, voltmeter selector switch, three ammeters and maximum demand indicator on incoming phases with associated CTs and VTs. Generally, the conventional instruments specified shall be housed in enamelled, square, metal cases for flush installation. Scales and markings shall be protected and sealed. Accuracy of instruments shall be within 2% unless otherwise specified.

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Voltmeters shall be of Moving iron type, range 1.25 times nominal system voltage, 90 degree angle, size 76 x 76 mm. Voltmeter Selector Switch shall be of 7-position rotary type. Ammeters shall be of Moving iron type, range 2 times nominal circuit amperage, 90 degree angle, size 76 x 76 mm. Provide Current Transformer (CT) dry type, rated secondary current 5A. Rated primary current, core size and accuracy are to be determined in accordance with nominal current of plant protected, short-circuit level and burden. Provide Voltage Transformer (VT) complete with primary and secondary fuses and disconnecting device.

3.1.7. Control Voltages The following control voltages are applicable for this project: MV Switchgear and LV Circuit breakers control voltage shall be 120 Volts DC LV switchgear accessories which are Integral mounted to the MDB, shall be self-powered or operate from 230V AC.

3.1.8 Battery System (125 V DC Power Supply) The MV tripping battery and charger shall be located in the LVAC switchroom for the double ended package substation. The single ended package substation shall contain the DC system in the Battery Room. Battery type shall be of Lead Calcium in sealed clear plastic or glass containers. The Battery sizing calculation shall be completed by the medium voltage switchgear Manufacturer. The Charger shall be of Static-type silicon rectifier equipped with automatic regulation and provision for manual and automatic adjustment of charging rate. The Battery Rack shall be of two-step rack with electrical connections between battery cells and between rows of cells. Generally, the whole package substation shall withstand the seismic requirements. The substation Compartments which contain the DC Power Supply system shall have air conditioning for the battery and charger equipment.

3.1.9 Raceways and Conduits All indoor Low voltage main distribution and sub-distribution Cables shall be XLPE (90C) insulated single core copper conductors fixed to cable trays / cable ladder.

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The final circuits for the emergency lights shall be fire resistant multi core cables, installed within the cable trays / cable ladder. All wiring/cables are to be routed in rigid steel conduits where exposed installations are subject to mechanical damage or in plenum spaces. LSZH cables are to be routed cable trays /ladder/rack where Cables are in return air plenums. Rigid heavy gauge PVC conduit (of the type detailed below) concrete encased shall be applied for outdoors Underground Conduit: Underground duct type: Type EPC-40-PVC rated for 90 C conductors for both in underground and above ground applications. For underground duct accessories, duct separators shall be Factory Fabricated rigid PVC interlocking spacers including Warning tape. Ducts for MV shall be NEMA Type EPC-40 PVC, in concrete encased duct bank. Ducts size to be cast in substation base slab for incoming concrete encased duct banks:-

160mm OD MV Cables 100mm OD - LV Cables 100mm OD Comms Cables

3.1.10. Disturbance and Interference

The package substation shall comply with following EMI disturbance and interference practices and standards:

Separation from EMI Sources Shall comply with BICSI TDMM and TIA/EIA-569-A recommendations. Exhibit D2 : CONTROL-VOLTAGE ELECTRICAL POWER CABLES 260523

Filters Factory installed to suppress conducted electromagnetic interference as required by MIL-STD-461E. Fabricate lighting fixtures with one filter on each ballast (within Luminaires) as required. Exhibit D2 - INTERIOR LIGHTING 265100

Luminaires Ballasts for Low Electromagnetic-Interference Environments: Comply with 47 CFR 18, Ch. 1, Subpart C, for limitations on electromagnetic and radio-frequency interference for consumer equipment

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Induced voltages Shall provide adequate grounding on all equipment to prevent the build-up of electromagnetic voltage potentials.

Screening Shall provide screening of panels, enclosures, devices, or components that emit interferences.

Cable screens All monitoring and control and communication cables shall be screened with one end earthed.

Lightning Protection Shall comply with IEC/BS EN 62305

Surge Protection devices Shall comply with IEC 61643

3.1.11. Outdoor Package Substation Housing

The housing enclosure for the Outdoor substation shall be of a single integrated metal housing type, comprising three totally segregated compartments, accommodating MV switchgear, transformer and LV switchgear. The Degree of protection shall be IP 54 for switchgear (MV or LV) enclosures and IP 23 for transformer housing.

MV and LV connections to corresponding transformer terminals are to be insulated and inaccessible without the use of tools. Housing shall be weatherproof, suitable for outdoor installation at particular location, rodent and vermin proof, high quality hot-dip galvanized sheet steel. Alternative housing materials shall be submitted for approval by the contractor.

The roof and walls of housing shall be thermally insulated to maintain temperature inside enclosure within acceptable limits. The transformer Compartments within the substation shall be naturally ventilated through sand trap louvred openings of size appropriate to vent the heat dissipated by equipment or transmitted by outside radiation.

The Transformer compartment shall have Lockable double swing doors. Access to transformer shall be through demountable bolted panels. It shall be impossible to reach equipment or live parts from outside the housing. Refer to SAS report for door security and other substation facilities provided by SAS.

The metal parts of housing shall be cleaned, primed with rust inhibiting and waterproofing primer and finished with corrosion and weather-resistant enamel and final coat of air drying enamel. Alternative finish may be used subject to approval.

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Identification and danger signs shall be made of heavy cast metal, each not less than 200 x 300 mm and installed on all sides of the substation.

Permanent fungicidal treatment shall be provided for switchgear interiors, transformer coils and cores, over current protective devices, instruments and instrument transformers and fungus inserts for cable ties etc.

3.1.12. Seismic Restraints

Equipment and systems to be installed in strict accordance with seismic codes shall comply with seismic force based on the 1997 Uniform Building Code zone 2A.

Switchgears shall comply with Fabricate and test switchgears according to IEEE 344 to withstand seismic forces defined in Division 26 Section "Vibration and Seismic Controls for Electrical Systems.

Equipment to be restrained includes the following: Battery Racks, Cable Trays. Package substations equipment to include Main Distribution boards & Sub distribution panel boards

Raceway and cable supports to comply as described in NECA 1 and NECA 101 can be increased by at least 30 percent in future without exceeding specified design load limits Secure raceways and cables to these supports with two-bolt conduit clamps.

3.1.13. General Purpose Power Circuits and Fixed Equipment Supplies

General power shall be provided within compartments for fixed equipment which require small power supplies via MCB SDB.

General purpose convenience 230V socket power outlets shall be provided within the compartments walls, via fused circuit.

Wiring will comprise LSF sheathed, single core, stranded copper conductor cables complete with separate insulated circuit protective conductor (CPC) and shall be contained in metal conduit and trunking systems.

Fixed equipment supplies for;

BMS Panel NAC Panel Comms Panel/SAS System SCADA Panel Battery & Charger system Air Conditioning

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3.1.14. Internal lighting In each room areas compact fluorescent lamps, IP65, suspended luminaries shall be used, via a fused circuit. Wiring for the lighting circuits will generally comprise LSF single core stranded copper conductor cables, complete with separate insulated CPC, and shall be contained in metal conduit and trunking systems throughout their entire length. Lighting design illuminance levels shall be as identified in the table detailed below. Where no figure is quoted, lighting design and illumination levels shall be as defined by the IES lighting handbook Code for interior lighting. Area Average Illumination Level

(Lux) MV Switchgear Room 300 LVAC Switchgear Room 300 Transformer Bays 300

3.1.15. Lighting Control Lighting controls shall be by means of local manual switches as required.

3.1.16. External lighting

Over each of the exit doors (both emergency and normal), a compact fluorescent, bulkhead luminaire shall be installed, via a fused circuit. The luminaires shall be controlled with a manual switch located within the substation. Exterior Luminaires shall be selected as not to fail in materials or workmanship, corrode, fade, stain, perforate, erode, or chalk due to effects of weather or solar radiation within specified warranty period.

3.1.17 Emergency Lighting Emergency luminaires shall provide a 10% output when operating under emergency conditions comparing to normal mains supply for 60 minutes. An external emergency luminaire will be provided adjacent to each final exit door.

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Emergency exit lighting shall be provided to highlight the emergency exit routes. Emergency exit luminaires shall be located above each emergency exit door and along the exit route to provide safe means of escape from the substation housing.

3.1.18 Earthing and Bonding Substation earthing and bonding system shall comply with BS 7671. The Outdoor package substation earthing shall comprise of two independent MV and LV earth mats / nests. The earth mats shall be connected to the respective main earth bars located in the main MV and LVAC switchrooms. Dedicated earth cables shall be run to dedicated earth bars in main plant areas where individual earth bars shall be located local to the distribution boards. Main, equipotential and supplementary earthing conductors will be provided using separate CPCs to comply with BS7671.

3.1.19. Lightning Protection

The Lightning Protection System shall be in accordance with BS6651 code, with supplementary surge protective devices fitted. All lightning protection systems shall be bonded to the building electrical earths. Test links shall be provided. The air termination system on the roof shall comprise of a number of copper cross tapes, and a number of final rods/air conductors. The air termination system shall be connected at roof level to the down conductor system. The down conductor system shall utilise the external steel columns or structural steelwork. At roof level and at ground level proprietary clamps shall be used to facilitate the tape to bar connection. The earth termination network shall consist of a number of earth rods installed within a dedicated inspection pit. The tape shall be run from the bar connection clamp to the earth electrode, via a wall mounted test clamp. Contractor shall ensure compliance with BS6651 when providing lighting protection on metallic roofs.

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3.1.20. Telecommunications and SAS Facilities

Within package substations cable containment shall be provided for the Data & Voice cables which shall be supplied and installed by others. The cable containment shall be run from the LVAC switchroom where the COMMS Panel shall be located to the various outlet locations detailed by others.

3.1.21. Testing

All installations throughout outdoor package substation will be tested to ensure compliance with BS7671. The Substation shall then be issued with a Test Certificate fully in accordance with BS7671. This will include compliance with regard to volt drop current carrying capacity of cables and equipment, insulation resistance, operation of RCDs, earth electrode resistance, isolation and switching, protection by barriers or enclosures, shock protection earth loop impedance, earth continuity and short circuit fault rating. In addition Test Certificates shall be issued for the Emergency Lighting, Fire Alarm, and lightning protection systems, all in accordance with their respective standards. 4.0. Mechanical Services Design

4.1 General Overview

This section describes the mechanical services design for Outdoor Package Substation in particular the Air conditioning system and Special Airport Services (SAS) for the control and monitoring system. The control and monitoring of the Package substation shall be via SCADA, BMS, NAC and Comms Panels located in the LVAC switchrooms. The two MV Switchrooms and single LVAC Switchroom within the Outdoor Package Substation shall be provided with air conditioning. The air conditioning system shall be provided based on space occupancy levels and to meet the cooling requirements for the building as detailed below in 4.1.2 and 4.1.3. The transformer compartments shall be naturally ventilated through sand trap louvered openings to dissipate heat from transformer or transmitted outside radiation. The Air conditioning system shall have local temperature controls for each area. All mechanical plant shall be sized with a 10% spare capacity for cooling. Refer to the project Mechanical standard specifications for materials, standards, testing,

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workmanship and documentation requirements.

4.1.2. External Temperatures & Conditions Design summer time and winter external condition to be used for the purpose of sizing cooling coils:

Summer conditions:

45 deg C dry bulb 29.4 deg C wet bulb

Winter conditions:

11.1 deg C dry bulb 9.7 deg C wet bulb

4.1.3. Internal Temperatures & Conditions

The internal summer and winter design temperatures are as follows:

Room Temperature C Electrical MV Switchrooms 26 2 Electrical LVAC Switchroom 26 2 Battery Room 26 2 The humidity control to rooms without specified levels will be via dehumidification of the air supply.

4.1.4. Internal Cooling Loads

The internal cooling load shall consist of the following major items: 1. Occupants 2. Equipment 3. Lighting 4. Ventilation 5. Infiltration 6. Building Fabric

4.2.1. Automatic controls SCADA, SAS and BMS The cooling systems for the Outdoor Package Substation will be automatically controlled and monitored by the BMS system. The system shall also monitor and control the operation of the Building Services Mechanical systems via NAC Panel.

ATK002-422-C240-FD-E-RPT-00012 23

Control systems shall maintain comfort conditions to those areas requiring a controlled environment, ensure safe operation of plant and systems, provide flexible timed operation of plant, optimise running costs and maximise energy efficiency. Building Management Systems (BMS) will be provided, and BMS outstation panel will be located within the LVAC Switchroom. The systems will have the capability to self learn optimum starting and stopping times for minimising energy wastage. The BMS will be networked within the outdoor substation and be capable of connection to the site wide BMS network infrastructure by means of connection to a communications node. The Outdoor Package Substation BMS network shall be run on a BACNet or LONWorks protocol. The BMS graphics and alarms software shall be generated as part of the building installation design and will be installed in the site wide monitoring head-end. Refer to the project report BMS Design Report ATK002-000-A000-FD-M-RPT-00001A.

4.2.2. Electrical Metering

The SCADA system shall pick up all multi function meters identified on the schematics by means of serial field network. As standard the SCADA shall monitor kW, kWh, Current per phase (3), Volts, kVA & kVAR. A wall mounted Digital Meter display in kWh shall be provided in the LVAC compartment.

4.2.3. Transformers

The SCADA shall monitor temperature and status of the Transformers. Monitoring shall alarm any critical or maintenance conditions.

4.2.4. Automatic Transfer and Static Switches

The SCADA shall monitor the position and status of each feed in the ATSs (Automatic Transfer Scheme) and Static Switches. Each MV and LVAC circuit breaker shall be controlled and monitored by SCADA Panel via the BMS system.

4.2.5. Fire Suppression The BMS controls will be interlocked with the Fire Alarm systems and cooling systems shall be shut down automatically by these systems.

ATK002-422-C240-FD-E-RPT-00012 24

5.0 Power Distribution System and Equipment

5.1.1. Package Substation Foundation and Enclosure

Steel Reinforced concrete foundation shall be used for the installation of package substation housing. This foundation shall be installed unified and suitable to accommodate 500, 1000, 1500kVA and 2000kVA transformer rating package substations. The housing shall be provided by the contractor. The housing base frame assembly shall be embedded on a concrete flooring (slab) as shown in the Slab drawing provided by Atkins. Floor plan layout with power and communication cable opening, equipment floor mounting are also detailed. The prefabricated package substation shall be designed for fast installation, maintenance free operation and safety for operator.

5.1.2. Substation Layout and Dimensions

5.1.2.1 MV Compartments

Refer to Atkins General Arrangement drawing for MV compartment layout and position of MV switchgear. The items to be installed;

2 No. 630A, 13.8kV, Fault making and load breaking MV Switchgear Bottom entry MV cable connection to switchgear. Plenum duct shall be installed.

5.1.2.2 Transformer Compartment

The transformer shall be located in an independent compartment to facilitate easy maintenance with double door access. The transformer shall be mounted in a bund within the compartment to capture any leaking oil.

1 No. MV Transformer oil type, 13.8kV/.042kV DYn11, ONAN, with Off load tap links +5% to -5% @ 2.5% steps on MV side. WTI indication with Alarm and trip.

Interconnection between Transformer LV side and LVAC Board shall via a Busduct arrangement (using Busbars, 3 phase and neutral)

Power Transformer Type shall be of sealed, liquid Immersed, 3-phase, two-winding, rated for continuous operation under site ambient conditions at full rated power,

ATK002-422-C240-FD-E-RPT-00012 25

naturally cooled (ONAN), with off-load, manual, externally operated tapchanger, lockable in all positions on primary side.

Transformer Standards shall comply with IEC 60076-1, 60156, 60296 and 60404-2.

Transformer construction shall be of variable volume steel tank, with corrugated wall design forming integral cooling pockets, heavy rolled and welded steel bottom and base frame and hermetically sealed bolted-on cover. Tank shall be completely filled with insulating liquid drawn in under vacuum. Tank cover shall have provision for two thermometers or temperature sensors, lugs for lifting, four lashing lugs and filler- pipe with valve. The tank shall have drain valve at bottom, earthing bolt on cover and earthing pad on base-frame, and a rating plate.

The transformer Noise Level shall conform to general A-weighted sound pressure

level measured at 1 m at any direction from transformer has to be less than 56 dBA.

Transformer Windings shall be copper, unless otherwise approved.

The Transformer Bushings shall be of porcelain type, tank-cover mounted, or tank-side mounted to manufacturer's standard, and as approved, with plug-in or bolt-on arrangements.

Transformer finish surfaces shall be to be steel grit blasted, caustic washed and

phosphatized, primed with waterproof primer and finished with weather-resistant enamel and final coat of air- drying enamel. Alternative finish may be used subject to approval.

The transformer Impedance Voltage at Rated Current shall be 5 % up to 1250 KVA

and 6% for higher ratings. .

5.1.2.3. LVAC Compartment LV Compartment shall be Air conditioned housing the following plant. Bottom entry cable connection shall be provided for all equipments below;

LVAC Switchboard including the PLC Panel section. 400V indoor Panel, 3 phase, 50Hz, 50kA 1sec. The LVAC Incomer and bus-section are ACB type.

BMS panel Building Management System for Mechanical Services

NAC Panel Network Access Controller for Mechanical Services

Comms Panel Communication Panels part of BMS.

SCADA Panel - Refer Title Load Centres SCADA PANELS FOR INSTALLATION AT PLANT LOCATIONS SHEET 3 OF 4, drawing number 422-C100-FD-X-03XX00- 003004

ATK002-422-C240-FD-E-RPT-00012 26

.

LV Compartment Construction: dead front type, consisting of main circuit breaker, busbars, outgoing circuit breakers, as required, instrumentation and accessories.

LV compartment main circuit breaker shall have a solid state trip unit with long-time, short time and ground-fault pick up and time- delay adjustments and with high instantaneous over-current trip, to correspond with transformer rating and LV interrupting capacity at location, time and current coordinated with MV protection on primary side and circuit breakers or protective devices downstream, as required.

LV compartment shunt trip device shall be provided, operated by pressure relief device and thermometer.

LV compartment busbar assembly shall comprise fully of insulated set of 3- phase and neutral copper busbars. The Neutral shall be fully rated. Earth bar is to be provided at lower end of compartment.

LV Compartment Outgoing Circuit Breakers: Type and rating as required, time/current coordinated with upstream and downstream LV distribution circuit breakers.

Connection to PLC system, including interface elements such as breakers, relays, transducers, etc. as specified and /or as required.

The dimensions of the LVAC Switchgear shall change according to the type of switchgear and number of outgoing feeders shown on the GA layout drawing for each substation.

5.1.2.4. Battery Room

110V DC Battery and Charger are located in the Battery Room for the single ended substation.

The Battery and Charger are located in the LVAC Switchroom for the Double ended substations.

5.1.3 Feeder Protection Following minimum protections shall be provided for incomers & bus-coupler:

ATK002-422-C240-FD-E-RPT-00012 27

Incomer

Hi set Instantaneous O/C Protection (50)

IDMT O/C Protection (51)

Instantaneous E/F Protection (50G)

IDMT E/F Protection (51G)

Under-Voltage Protection (27) The circuit breakers shall be monitored and controlled locally via the SCADA system.

5.1.4 Standby Supply The MV Standby supply for the Outdoor substation shall be derived from the centralised MV generators located in the Load Centre. When the normal supply is restored, the power supply arrangement will automatically (or manually) be reverted back to the normal supply from the generator supply. The automatic changeover from mains to generator and vice-versa is achieved through the BMS and the SCADA system.

5.1.5. Outdoor Feeder Cables MV and LV Feeder cables shall be run in concrete encased duct banks. No directly buried cables are to be used. Manholes shall be provided every 80m maximum and at intersections / bends. In addition, manhole covers/frames are to be water tight, double seal, heavy duty, cast iron type. Adequate space between telecommunication and power cables shall be allowed to eliminate electromagnetic interference. Substation foundation slab shall be provided with earth ducts for external earthing of LV and MV earth mats.

5.1.6. Electrical Installation Electrical plant installations in the package substation shall include:-

MV Transformer MV Switchgear LVAC main distribution boards /PLC Panel BMS systems

ATK002-422-C240-FD-E-RPT-00012 28

NAC Panel Comms Panel/SAS System SCADA Panel Battery & Charger system Interior Lighting systems External lighting Outdoor CCTV Door Security System General small power system Emergency lighting system- General services/systems containment Lightning protection systems Earthing systems

Exact locations and physical layout of equipment and components may be varied as required to suit manufacturer's design and as approved, provided the required functions and operations are accomplished. Contractor to ensure that concrete bases and foundations provided for installation of equipment are constructed in accordance with approved shop and construction drawings and equipment manufacturers' drawings and that holes for fixing bolts and provisions for passage of cables etc. are provided as required. Contractor to ensure that trench construction and covers provided for installation of power and control cables are in accordance with approved shop and construction drawings. Contractor to ensure that equipment supports, fixings and the like, and sleeves for passage of feeders and cables which are to be built into concrete foundations, bases, cable trenches or building structure are provided as and when required and that they are properly installed. Equipment to be installed on concrete bases etc. and assembled completely plumb and level, before grouting in holding-down bolts. Supports and terminations of all installed incoming and outgoing cable supports, cable ends and termination fittings required for MV, LV and control cables. Any relays should be set in accordance with manufacturer's instructions and the Local Power Authorities requirements. The earthing installation shall be as described in Atkins report Grounding General Requirements report. Remove temporary lifting eyes, channels, brackets, and temporary blocking of moving parts from the switchgear units and other equipment where temporary lifting provisions are provided.

ATK002-422-C240-FD-E-RPT-00012 29

5.1.7. Earthing Installation

The system shall be designed and installed to provide a safe and effective earthing system in accordance with BS 7430, BS7671 including Amendments 1 and applicable local regulations and to meet with the following requirements. Provide sufficiently low impedance path, which shall ensure the satisfactory operation of protective devices under fault conditions. Restrain system voltages within reasonable limits under fault conditions (such as lightning, switching surges or inadvertent contact with higher voltage systems) and ensure that insulation breakdown voltages are not exceeded. Limit the voltage to earth on conductive materials which enclose electrical conductors or equipment. Ensure the operation of the primary protective devices when a fault occurs between the high and low voltage windings of a transformer. Provide an alternative path for induced current and thereby minimize the electrical noise in cables. The overall resistance of the grounding system to the mass of earth shall be less than 0.5 Ohms. Clean earths shall have an earth impedance of less than 1.0 Ohm. The LV grounding system shall be comprised of earth rods, riser conductors, earth terminals located in plant rooms and are interconnected using copper conductors and bonding conductors from earth terminals to all electrical equipment, metallic enclosures, steel cable containment, structural steel members and steel reinforcement of the building. Grounding system for SAS-ICT shall provide a clean earth via single point of earthing as shown on drawings. The earthing design including depth, size and quantity of ground shall be based on a provisional figure given in the Atkins earthing report. The actual soil resistivity test results and re-calculation will be provided by the specialist sub-contractor to determine the required number of earth rods to achieve the required resistance to earth. The installation contractor shall install any required number of earth rods to achieve the required resistance to earth. Earthing cable Main earthing conductor shall be 120mm2 bare copper The 13.8/0.42kV transformer LV point shall be directly connected to the main LV earth bar (TNS system). The physical separation between MV and LV earthing rods shall be adopted in addition to a min of 2 times of one rod length distance between any two earthing rods outside any outdoor package substation.

ATK002-422-C240-FD-E-RPT-00012 30

The main MV earth bar and the main LV earth bar shall not be connected together. MV and LV earth rods groups shall be connected together via test links. Separate communications shall be Clean Earth < 1 Ohms The Earth rods shall be 16mm diameter and 2.4m long.

5.1.8. Lightning Protection Installation

The lightning protection system shall be designed to IEC/BS 62305 and to meet with the following requirements. The lighting protections systems shall include the following:

Roof mounted air terminals

External down conductors along housing structures and bonding connection to housing structure reinforcement at selected points.

Bonding connections between down conductors and building re-bars at upper and lower level of the building when re-bars are used as down conductors.

Lightning earth pits consisting of earth electrodes and pit covers.

Disconnection facility of lower portion of the conductor or lighting protection earth pits themselves for necessary periodic testing of ground electrodes.

Perimeter conductor electrically linking all lightning protection earth pits together.

Any cross bonding conductor that may be required by pylon installation contractor.

The entire Lightning system earth resistance shall be not exceed 10 ohms. The lightning protection system (LPS) earth pits shall be distinctively identified from earthing system earth pits while maintaining a suitable clearance allowed by the code. All LPS earth pits shall be lined by a tinned copper ground ring conductor directly buried at a minimum depth of 600mm. The metallic enclosures of mechanical equipment and steel cable containment at roof top are cross bonded to the lightning protection system to avoid side flashing during a lightning discharge.

ATK002-422-C240-FD-E-RPT-00012 31

5.1.9 Estimated Maximum Demand and Transformer Rating The total electrical load of the Auxiliary Electrical Stations has been calculated, details of which can be found in the load schedules. The estimated maximum demand are summarised below: Table-1

Package Substation

Single/ Double

Estimated Load

Total Load (Est. +30%) Transformer

Size kVA

Supply Load

Centre KVA kVA

AES 1 DOUBLE 328 426.4 500 C AES 2 DOUBLE 990 1287 1500 C AES 3 DOUBLE 144 187.2 500 C AES 4 DOUBLE 137 178.1 500 C AES 5 DOUBLE 840 1092 1500 C AES 6 SINGLE 49 63.7 500 A AES 7 DOUBLE 175 227.5 500 C AES 8 DOUBLE 175 227.5 500 A

The normal supply loads are those that will usually operate during normal operation of the Load Centres. The emergency/standby supply loads are those which shall be backed up by the MV generators located in the Load Centres in the event of loss of normal supplies feeding the Package Stations. The standby loads include:

ATK002-422-C240-FD-E-RPT-00012 32

A. Appendix

A.1 Auxiliary Electrical Substation Drawing list

Drawing No. Title

MEDIUM AND LOW VOLTAGE NETWORK

AES 1

Rev

422-C240-FD-E-00XX07-001100 LEGENDS & SYMBOLS A

422-C240-FD-E-00XX07-002100 ABBREVIATIONS & GENERAL NOTES A

422-C240-FD-E-01XX07-001100 SUBSTATION GENERAL ARRANGEMENT AES1 A

422-C240-FD-E-03XX07-001100 POWER SINGLE LINE DIAGRAM AES1 A

422-C240-FD-E-03XX07-031100 SCADA PANEL INPUT / OUTPUT LIST A

422-C240-FD-E-03XX07-041100 BMS ARCHITECTURE SCHEMATIC A

422-C240-FD-E-10XX07-002100 EARTHING SYSTEM SCHEMATIC A

422-C240-FD-E-11XX07-002100 LIGHTNING PROTECTION A

422-C240-FD-E-15XX07-002100 MV PROTECTION DRAWING A

422-C240-FD-X-15XX00-002003 PROTECTION WITH FAULT LOCATIONS A

422-C240-FD-X-15XX00-003003 PROTECTION WITH FAULT POSITION TABLE A

422-C240-FD-E-19XX07-001100 STANDARD DETAIL A

422-C240-FD-C-19XX07-002100 DOUBLE ENDED BASE SLAB DETAILS A

Drawing No. Title


AES 2

Rev



ATK002-422-C240-FD-E-RPT-00012 33












Drawing No. Title


AES 3

Rev














ATK002-422-C240-FD-E-RPT-00012 34

Drawing No. Title


AES 4

Rev














Drawing No. Title


AES 5

Rev










ATK002-422-C240-FD-E-RPT-00012 35





Drawing No. Title


AES 6

Rev













422-C240-FD-C-19XX07-001100 SINGLE ENDED BASE SLAB DETAILS A

Drawing No. Title


AES 7

Rev





ATK002-422-C240-FD-E-RPT-00012 36










Drawing No. Title


AES 8

Rev














ATK002-422-C240-FD-E-RPT-00012 37

Address Email: Telephone: Direct telephone: Fax:

Document History1.0 Abbreviation and References1.1. Abbreviations1.2. References NECA: Standard Practices for Good Workmanship in Electrical Construction (ANSI)

1.3 Client References1.4 Atkins References2.0 Introduction3.0 The Basis of Design3.1. Design Criteria3.1.1. Climatic Conditions:3.1.2. Site Infrastructure3.1.3. Auxiliary Electrical Substations3.1.4. MV Switchgear3.1.5. LV Distribution Network3.1.6. Metering Instruments3.1.7. Control Voltages3.1.8 Battery System (125 V DC Power Supply)3.1.9 Raceways and Conduits3.1.10. Disturbance and Interference3.1.11. Outdoor Package Substation Housing3.1.12. Seismic Restraints3.1.13. General Purpose Power Circuits and Fixed Equipment Supplies3.1.14. Internal lighting3.1.15. Lighting Control3.1.16. External lighting3.1.17 Emergency Lighting3.1.18 Earthing and Bonding3.1.19. Lightning Protection3.1.20. Telecommunications and SAS Facilities3.1.21. Testing

4.0. Mechanical Services Design4.1 General Overview4.1.2. External Temperatures & Conditions4.1.3. Internal Temperatures & Conditions4.1.4. Internal Cooling Loads4.2.1. Automatic controls SCADA, SAS and BMS4.2.2. Electrical Metering4.2.3. Transformers4.2.4. Automatic Transfer and Static Switches4.2.5. Fire Suppression

5.0 Power Distribution System and Equipment5.1.1. Package Substation Foundation and Enclosure5.1.2. Substation Layout and Dimensions5.1.2.1 MV Compartments5.1.2.2 Transformer Compartment5.1.2.3. LVAC Compartment5.1.2.4. Battery Room5.1.3 Feeder Protection5.1.4 Standby Supply5.1.5. Outdoor Feeder Cables5.1.6. Electrical Installation5.1.7. Earthing Installation5.1.8. Lightning Protection Installation5.1.9 Estimated Maximum Demand and Transformer RatingA. AppendixA.1 Auxiliary Electrical Substation Drawing list

atkins

Documents

electrical installation

electrical metering

atkins references

internal lighting

battery system

feeder protection

power distribution system

transformer compartment