EEX10401 Industrial Facility Substation

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Industrial Facility Substations:

Functions, Design Considerations,
Types, And Major Components
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s
employees. Any material contained in this document which is not
already in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Chapter : Electrical For additional information on this subject, contact

File Reference: EEX10401 W. A. Roussel on 874-1320
Engineering Encyclopedia Electrical
Industrial Facility Substation: Function, Design, etc.
CONTENTS PAGES
INTRODUCTION.................................................................................................... 1
FUNCTIONS OF A SUBSTATION ...................................................................... 2

Voltage Transformation .................................................................... 3
Circuit Switching .............................................................................. 3
Voltage Regulation ........................................................................... 4
VAR Control..................................................................................... 4
System Protection ............................................................................. 4
DESIGN CONSIDERATIONS ............................................................................. 4
Safety ................................................................................................ 4
Simplicity.......................................................................................... 4
Reliability.......................................................................................... 5
Maintenance...................................................................................... 5
Flexibility.......................................................................................... 5
TYPES OF SUBSTATION CIRCUIT ARRANGEMENTS.................................... 6
RADIAL SYSTEMS .......................................................................................... 6

Simple Radial System ....................................................................... 6
Expanded Radial System .................................................................. 6
LOOP SYSTEMS ............................................................................................. 8
Primary Loop System ....................................................................... 8
Secondary Loop System ................................................................... 8
SELECTIVE SYSTEMS ..................................................................................... 8
Primary Selective System ................................................................. 8
Secondary Selective System ........................................................... 11
Combined Selective System ........................................................... 11
MAJOR SUBSTATION COMPONENTS............................................................. 15

INTRODUCTION ........................................................................................... 15
BUSES ......................................................................................................... 15
Open Bus (Rigid) ............................................................................ 15
Non-Rigid or Strain Bus ................................................................. 15
Phase Arrangements ....................................................................... 15
SWITCHES ................................................................................................... 17
Isolating Switch .............................................................................. 17
Magnetizing Current-Break Switch ................................................ 17
Load Interrupter or Load-Break Switch.......................................... 18
Disconnect or Isolating Switch (Medium Voltage)......................... 22
Outdoor Group-Operated Switch .................................................... 22
TRANSFORMERS .......................................................................................... 23
Liquid-Filled Type Transformers.................................................... 23
Dry-Type and Cast Coil Type Transformers................................... 24
Gas-Filled Transformers ................................................................. 24
METAL-ENCLOSED POWER SWITCHGEAR ................................................... 24
Metal-Clad Switchgear (601 - 15,000 V)........................................ 26
Low Voltage Switchgear (Up to 600 V) ......................................... 27
Interrupter Switchgear (601 - 34500 V).......................................... 28
Station-Type Cubicle Switchgear ................................................... 28
MEDIUM AND HIGH VOLTAGE CIRCUIT BREAKERS .................................... 30
Oil Circuit Breakers ........................................................................ 30
Sulfur-Hexafluoride (SF6) Gas Circuit Breakers............................ 30
Vacuum Circuit Breakers................................................................ 31
Air-Magnetic Circuit Breakers........................................................ 32
POWER FUSES ............................................................................................. 32
Current Limiting Power Fuses (CLF) ............................................. 33
Non-Current Limiting (Expulsion) Power Fuses ............................ 35

E-Rated Power Fuse Time/Current Characteristics......................... 35

Electronic Power Fuses................................................................... 39
INSTRUMENT TRANSFORMERS .................................................................... 42
Current Transformers (CTs)............................................................ 43
Voltage Transformers (VTs) ........................................................... 43
CONTROL HOUSE ........................................................................................ 43
Protective Relays ............................................................................ 43
DC Control System Battery ............................................................ 44
Metering and Instrument Equipment .............................................. 47
Air-Conditioning Equipment .......................................................... 48
MISCELLANEOUS COMPONENTS .................................................................. 48
Steel Structures ............................................................................... 48
Insulators......................................................................................... 48
Surge or Lightning Arrestors .......................................................... 48
Grounding System .......................................................................... 51

Industrail Facility Substation: Function, Desing, etc.
INTRODUCTION
Substations are commonly supplied by voltages ranging from 15 to 230 kV-class utility or
user owned distribution systems. Figure 1 shows a basic power and transmission distribution
system with the following types of substations:
• Generating plant substation
• Transmission substation
• Large, medium, and small industrial substations
A large or medium industrial substation is typically used to transform a higher utility voltage
to a plant’s lower distribution or utilization voltage level. Industrial substations (medium and
large) are normally dedicated to serve a single industrial plant with loads greater than 5 MVA
and commonly include one or more transformers. Unit type substation sizes typically range
from 500 to 3000 kVA.
Note: This Module serves as an introduction to the remaining Modules of this Course.
Saudi Aramco DeskTop Standards 1

Figure 1. Electrical Power System
Functions of a Substation
Although a substation performs many functions, the five major functions of a substation
consist of the following:
• Voltage Transformation
• Circuit Switching
• Voltage Regulation
• VAR Control
• System Protection

Figure 2 is a one-line diagram illustrating the major functional components of a substation.
Voltage Transformation
Voltage transformation from high to low voltage is accomplished in any one of several
different ways, with the most common being a single three-phase transformer or three single-
phase transformers. In industrial substations, a three-phase transformer makes a neater, more
compact substation, reduces the number of bushings, fittings, cable connections, etc., and is
typically easier to inspect and maintain.
Circuit Switching
Circuit switching can also be accomplished by several means. No-load switches, load-break
switches, fused disconnect switches, and, in Saudi Aramco substations, both low and medium
voltage circuit breakers are the most common form of switching electrical circuits.
Figure 2. Substation Functions

Voltage Regulation
Most substations require some form of voltage regulation. Very large substation transformers
use automatic + 10% load tap changers (LTC), with 33 steps, each step 0.625%, to regulate
the voltage. Most other substations use + 5% no-load tap changers (NLTC), with 5 steps,
each step 2.5%, to regulate the voltage. Very large utility transmission substations use
separate voltage regulators to regulate the voltage. Voltage regulators are not often used in
industry substations, but are available if voltage problems warrant their use.
VAR Control
VAR control is the planned control of the reactive power (current) in an electrical system.
VAR control of an industrial system is most often accomplished using power factor correction
capacitors. Note: Saudi Aramco installations do not use VAR control in their industrial
substations.
System Protection
System protection is accomplished by means of fuses, circuit breakers, lightning arrestors,

and protective relays. For example, an overcurrent relay (ANSI Device 51) protects the
system from overloads and faults, whereas a lightning arrestor protects the transformer from
overvoltages caused by lightning strikes or switching surges.
Design Considerations
Many factors, such as the following, need to be considered before beginning design of an
industrial substation: safety, simplicity, flexibility, reliability, and maintenance.
Safety
Human safety and property damage prevention are the two most important factors in the
design of a substation. The design engineer must always assume the public or others within
the plant are not aware of the dangers that are present in a substation. The engineer also
needs to consider the safety of personnel who will be working on or around the electrical
equipment in the substation.
Simplicity
The more simple a substation is designed to operate, the more safe and reliable it is to
maintain and operate. As the equipment in the substation increases, it becomes more complex
to operate, and correspondingly, the substation becomes less reliable.

Reliability
Providing continuous power to loads is very important. Engineers call the ability to supply
power to a location “reliability”, and they know that it is not possible to provide power to a
load 100% of the time. Therefore, the engineer must consider other factors in the design of
the system. The level of reliability required is dependent on the facility. If a facility can
remain without power for a long period, a less reliable system can be designed and installed.
If a facility is critical in nature, redundant or parallel systems should be installed to improve
reliability of the system. The following factors affect the reliability of the substation:
• Bus configuration and circuitry
• Equipment and incoming line redundancies
• Quality of the equipment in the substation
• Relay and switching equipment. The relays and switching equipment must be properly
applied and coordinated, which allows a fault to be quickly isolated and ensures only the
smallest portion of the plant is disconnected.
Maintenance
The design of the substation must consider the need for maintenance. The substation
equipment must be easy to access and space must be provided for inspection, adjustment, and
repair of the electrical equipment. Maintenance is also a major safety concern for plant
engineers.
Flexibility
The substation should include plans for expansion. The engineer needs to consider the plant
voltages, equipment ratings, space for additional equipment, and the capacity for increased
loads. Designing flexibility into a substation today could save many resources (time and
money) in the future.

TYPES OF SUBSTATION CIRCUIT ARRANGEMENTS
A variety of basic circuit arrangements is available for the distribution of electrical power in
an industrial plant. Selection of the “best” system depends upon the need of the
manufacturing process, for example, a refinery. Reliability of the power supply depends upon
the load. For example, a simple radial system is probably adequate to supply a housing area,
whereas a more sophisticated, expensive, and reliable loop system is required to supply a
critical refinery process. This Information Sheet will briefly describe the following types of
substation circuit arrangements:
• Radial Systems
• Loop Systems
• Selective Systems
Radial Systems
Figure 3a illustrates a simple radial system and Figures 3b and 3c illustrate expanded radial
systems.
Simple Radial System
A simple radial system (Figure 3a) looks like an inverted tree. A single primary service and
transformer serve the entire load. There is no duplication of electrical equipment (cables,
breakers, etc.) and the system investment is the least expensive of all of the types of circuit
arrangements. The operation and expansion of the radial system is simple and the reliability
is high if high quality components are used. The radial system is also a relatively easy system
to perform a short circuit or coordination study. Unfortunately, loss of a single cable,
transformer, etc., will shut down the entire system. The equipment must also be shut down to
perform routine maintenance. The simple radial system is an adequate power system circuit
arrangement for most non-critical process loads.
Expanded Radial System
The expanded radial system (Figures 3b and 3c) is just an expansion of the simple radial
system, and it is used to supply power to multiple unit substations near major load centers.
The advantages and disadvantages described for simple radial systems also apply to expanded
radial systems.

Figure 3. Radial Systems

Loop Systems
There are two types of loop systems: a primary loop system and a secondary loop system,
which is more often called a secondary selective system with a normally-closed tie breaker.
Primary Loop System
A primary loop is more reliable than a radial system. If one source feeder fails, the other
source feeder supplies the load. The loop system is more dangerous to work on than the
radial system because power is supplied from both directions to the load. Fault duties are
typically double that of a radial system because the parallel feeders’ impedance is 50% of the
single radial feeder impedance. Loop systems provide greater reliability for critical loads
because single faults will not isolate the system. Loop systems are also more expensive
because of the duplication of equipment. Short circuit studies performed on loop systems are
more tedious, and coordination studies performed on loop systems are much more complex
because of the need to use directional relays. Figure 4 illustrates two types of primary loop
circuit arrangements. If any of the normally-closed (N.C.) switches illustrated in Figure 4 are
opened, the system reverts back to a simple radial system.
Secondary Loop System
Secondary loop is not an ANSI/IEEE preferred term. Secondary loop implies that the system
is a secondary selective system with a normally-closed (N.C.) tie breaker. Secondary
selective systems will be described in the next section of this Information Sheet.
Selective Systems
Selective system circuit arrangements are either primary selective, secondary selective, or a
combination of both.
Primary Selective System
Loss of a primary source can be protected against by use of a primary selective system
(Figure 5), where each transformer is supplied by two sources. Normal operation is to supply
half the load (transformer) from one source, with the other source acting as the alternate
(emergency) source. Switching of the load (transformer) over to the alternate source can be
manual or automatic, but there will be a power interruption until the load is transferred to the
alternate source.

Figure 4. Loop Systems

Figure 5. Primary Selective System

Secondary Selective System
If pairs of unit substations transformers (double-ended substation configuration) are

connected through a normally open (N.O.) tie breaker, the system is called a secondary
selective system (Figure 6a). Each unit substation normally carries half the load, and in the
event of a failure of the normal source, or for routine normal maintenance, the N. O. tie
breaker is closed. The secondary selective system is the preferred Saudi Aramco circuit
arrangement for large unit substations. For routine maintenance purposes, Saudi Aramco
operating standards require closing of the N. O. tie breaker before opening one of the main
breakers. If the substations are geographically remote from one another, two tie breakers are
used for selective switching purposes, as illustrated in Figure 6b.
Combined Selective System
The combined selective circuit arrangement system (Figure 7) is simply a combination of both
the primary and secondary selective systems. Figure 8 illustrates an alternative type of
combined selective system.

Figure 6. Secondary Selective Systems

Figure 7. Combined Selective System

Figure 8. Alternate Combined Selective System

MAJOR SUBSTATION COMPONENTS
Introduction
This Information Sheet will briefly describe the major substation components and it also
serves as an introduction to the remaining Modules of this Course.
Buses
Buses used in outdoor substations are typically one of the following two types:
• Open Bus (Rigid)
• Non-Rigid or Strain Bus
Open Bus (Rigid)
Open bus carries the power from incoming transmission lines to the transformer. Between
sections of bus, there may be circuit breakers and switches. Open bus is usually constructed
of aluminum material, but copper is used as well. The size of the conductor (bus) should be
selected so that the conductor temperature does not exceed 700C in an ambient temperature of
500C. The supports for open bus should allow for movement of the bus due to changes in
temperature.
Non-Rigid or Strain Bus
Many smaller outdoor substations also use a non-rigid or strain bus instead of a rigid bus. A
strain bus is an aluminum conductor that is steel-reinforced and is stretched between two
supporting structures. This type of steel-reinforced wire is abbreviated as ACSR/AW.
Typically the wire is stretched over the top of transformers and both the primary and
secondary leads are dropped down from the strain bus to the transformer bushings.
Phase Arrangements
Arrangement of phases within an outdoor substation will always be the same. Phases are
always labeled 1-2-3. If the bus work is arranged so that the bus runs East and West, the
North bus is labeled phase 1 and the South bus is labeled phase 3, as illustrated in Figure 9.
If the bus work is arranged so that the bus runs North and South, the East bus is labeled phase
1 and the West bus is labeled phase 3, as illustrated in Figure 10.
If the bus work is arranged so that each phase is directly below the other, the top bus is
labeled phase 1 and the bottom bus is labeled phase 3, as illustrated in Figure 11.

In all cases, phase 1 is connected to the H1 and X1 bushings of the transformer. The H2 and
X2 bushings of the transformer are connected to phase 2 and the H3 and X3 bushings are
connected to phase 3.
A set of three identification plates indicating the phase number should be mounted on the
lower support structure of each air break switch. These identification plates must be easily
visible from the ground.
Figure 9. Bus Arrangement North-to-South (Top-View)
Figure 10. Bus Arrangement East-to-West (Top View)

Figure 11. Bus Arrangement Top-to-Bottom (Side View)
Switches
Switches can be classified by many different characteristics, for example, voltage (i.e., low,
medium, high), interrupting medium (i.e., vacuum, air), outdoor, indoor, etc. For purposes of
this Information Sheet we will limit the discussion to low and medium voltage switches.
Isolating Switch
An isolating switch does not have an interrupting or load-breaking capability. The only
purpose of an isolating switch is to provide isolation of a circuit or load. An isolating switch
cannot be operated until all current has stopped flowing in the circuit, which means that
another device must be used in the circuit for protection and interruption of the load. An
isolating switch is always operated manually.
Magnetizing Current-Break Switch
Magnetizing current-break switches are designed to interrupt the magnetizing (inrush) current
of the transformer, which is approximately 8 to 12 times the primary full-load amperes rating
of the transformer. The load must be removed (secondary main breaker opened) before
operation of a magnetizing current-break switch.

Load Interrupter or Load-Break Switch
There are two types of low voltage interrupter or load-break switches: one type is often called
a safety switch and the other type is often called a bolted pressure switch. The two types of
medium voltage load interrupter switches are called air load-break and liquid-filled switches.
Safety Switch - A safety switch is a load-break device, which means the switch has the ability to
interrupt normal load current flowing through it, but it cannot interrupt fault current. The
safety switch has a low short circuit or interrupting rating. The switch is fast acting and has a
quick-make/quick-break mechanism, which means that the contacts open and close very
quickly. Safety switches can be fused or unfused and are rated in horsepower, current, and
voltage. The switch can safely interrupt the stall or locked-rotor current of the motor, which
is calculated at approximately six times the full load current of the motor. Figure 12 shows a
typical low voltage safety switch. A safety switch is always manually operated. Application
of this type of switch requires a continuous current rating of at least 125% of the expected
continuous load current.
Figure 12. Low Voltage Safety Switch

Bolted Pressure Switch - The last type of low voltage switch is an interrupter switch, which is
also known as a bolted pressure switch. An interrupter switch has a quick acting mechanism
that allow the switch contacts to close and open very quickly. Typically an interrupter switch
can safely interrupt at least 12 times its continuous current rating. Bolted pressure switches
are found in panelboards, small motor control centers, and switchboards. The interrupter
switch can be supplied with or without fuses. When combined with current limiting fuses,
interrupting ratings can be as high as 200 kA. Continuous current ratings range from 600 to
6000 amps. Bolted pressure switches are normally manually operated, but they are also
commercially available with an electrical trip.
Air Load-Break Switch - The air load-break switch is in a metal enclosed assembly and is
classified as metal-enclosed switchgear. Note: Requirements for metal-enclosed switchgear
are discussed in a later Module. The switchgear can contain instrument and control power
transformers, metering, protective relaying, control wiring, and accessory devices. The
enclosure can be either an indoor or outdoor design. Some air switches allow the internal
components to be rolled out from the enclosure, which allows fuses to be replaced without de-
energizing the incoming circuit, and it also provides for easy inspection and maintenance. Air
switches can be assembled as individual switches or combined into a distribution line-up, and
they can be mechanically interlocked with other switching devices.
To ensure fast closing and opening speed, the air switch mechanism has a stored energy
device. When operating the closing handle, a large spring charges or compresses. Once
charged, the spring is released and the stored energy of the spring operates the switch. This
spring action occurs in both the opening and closing operations. The switch design allows
only about 500 operations. Therefore, an air switch should not be used when frequent
operation is required.
There are two separate sets of contacts on an air load-break switch: the main contacts and the
arcing contacts. The main contacts carry the load current and the arcing contacts interrupt the
current. Always avoid arcing on the main contacts. Damage to the main contacts causes a
high contact resistance on the switch, which causes heating and may result in failure of the
switch.
Under normal operation, the main contacts carry most of the current. As the main contacts
open, all current is transferred to the arcing contacts. There is no arcing on the main contacts.
At a preset point in operation, the arcing contact is released and opens at a very high speed.
This high speed opening, combined with the action of an arc chute, extinguishes the arc, and,
thereby safely de-energizes the circuit. All three phases are operated from a common
operating mechanism. The switch’s quick-make/quick-break mechanism interrupts full load
current while the fuses provide short circuit protection. Depending on the requirements, the
fuses can be either current limiting or non-current limiting.

The air load-break switch has several application advantages over an oil-filled switch, which
include the following:
• A visible air break is provided so that there is no doubt as to whether the switch is open
or closed.
• The insulating medium is air, and therefore it cannot leak and does not require any
maintenance.
• The switch contacts are accessible for testing and phasing of circuits.
• Since there is no liquid, there is less danger of the switch exploding, if used above its
capability.
The main disadvantage of an air switch is that it is larger than a liquid-filled switch. Since air
is the insulating medium, all electrical distances are greater than in a liquid-filled switch.
Figure 13 shows a typical air interrupter switch.

Figure 13. Typical Medium Voltage Air Load-Break Switch

Liquid-Filled Switches are usually filled with mineral oil. Older switches were filled with
mineral oil or Askarel, however, for environmental reasons, Askarel is no longer used. The
liquid-filled switch is small and compact. All the advantages listed under the air switch are
limitations in liquid-filled switches. Liquid-filled switches are usually designed to interrupt
only the magnetizing current of a transformer. Note: Saudi Aramco does not permit the use
of liquid-filled switches because they have proven to be a safety hazard to operating
personnel.
Disconnect or Isolating Switch (Medium Voltage)
A disconnect or isolating switch can only interrupt a very low current. The maximum current
that this switch can interrupt is a transformer’s magnetizing current or line charging current.
A disconnect switch cannot interrupt normal load or fault current. If the switch is required to
interrupt a magnetizing or line charging current, it should be equipped with arcing horns. The
arcing horns assist in interrupting the small current. This switch should also be mounted on
top of the substation structure, with no energized conductors placed above the switch. If an
energized conductor is above the switch, the ionized air created by the arc could cause
damage to the adjacent energized conductors. Some types of medium voltage outdoor
disconnect switches are equipped with a nozzle that blows a blast of high pressure air between
the stationary and moving contacts when the switch is opened, which helps extinguish the arc.
Outdoor Group-Operated Switch
Figure 14 shows one phase of an outdoor group-operated switch. Usually three phases are
mechanically connected to an operating mechanism. This type of group-operated switch is
sometimes combined with fuses. This combination of switch and fuse is widely used to
disconnect and protect transformers in both medium and high voltage large outdoor
substations.
Some outdoor group-operated switches are designed to interrupt load current and low level
fault current without any external arcing. Because there is no arc, an interrupter switch can be
mounted in any position without concern for adjacent conductors. Interrupter switches
usually have the contacts inside a vacuum or an SF6 chamber. All arcing is contained inside
this chamber. The majority of interrupter switches are manually operated with the operating
mechanism accessible from the ground. Motor-driven operated mechanisms also are
available. Use of motor-driven operating mechanisms allow automatic control of interlocked
switches from remote locations.

Figure 14. Group-Operated Outdoor Switch (One-Phase)
Transformers
There are four basic types of power transformers: dry-type, liquid-filled, non-flammable
liquid-filled, and gas-filled.
Liquid-Filled Type Transformers
Oil-Filled transformers have the lowest cost of any other type of power transformer, but their
use is primarily for outdoor applications. The mineral oil is flammable, and therefore it
cannot be used indoors, except in specially designed transformer vaults. Oil-filled
transformers are suitable for use in dirty and dusty areas, as well as adverse weather
conditions.
Non-Flammable Insulating Liquid-Filled type transformers can be used indoors and are best suited
for indoor applications where the environment is dirty, dusty, or corrosive. Silicone is the
most common type of non-flammable insulating liquid used in these types of power
transformers.

Dry-Type and Cast Coil Type Transformers
Dry-type and cast coil transformers are used for indoor applications at low and medium
voltage classes. The location must be dry and well ventilated so that cooling air may move or
be forced across the windings and core. Dry-type transformers are applied at load centers and
other locations where high costs are an issue, because dry-type transformers are less
expensive than fluid-immersed units. Dry-type transformers are air-cooled and air-insulated
for use in buildings and industrial locations near the intended load. Dry-type transformers are
also free of explosive hazards and contain few or no organic materials. Class H insulation
must be specified for dry-type transformers.
In a cast coil transformer, the windings are completely covered by an epoxy resin. The
epoxy resin provides enhanced protection of the windings from atmospheric contaminants.
For most indoor applications the cast coil transformer is preferred over the standard dry-type
transformer; the cast coil transformer has many advantages over the standard dry-type
transformer. Cast coil transformers are unaffected by humidity, their windings are easier to
replace than standard dry-type transformers, they are less likely to trap dirt and sand, they are
less noisy, and they have a better insulation system.
Gas-Filled Transformers
Gas-filled transformers are used where liquid-filled transformers cannot be used. The gas
used in these types of transformers is fluorocarbon which is non-flammable and non-
explosive. Gas-filled transformers can be used indoors or outdoors. The major disadvantage
of gas-filled transformers is cost; they are very expensive transformers.
Metal-Enclosed Power Switchgear
Note: Metal-clad, low voltage, and interrupter type switchgear will be described, in detail, in
a later Module of this Course.
Figure 15 shows the four enclosure classifications for metal-enclosed power switchgear. The
four enclosure classifications are metal-enclosed low voltage power circuit breaker
switchgear, metal-enclosed interrupter switchgear, metal-clad switchgear, and metal-enclosed
station-type cubicle switchgear.

Switchgear also contains electrical insulating barriers that provide electrical isolation between
adjacent cubicles. Metal-clad switchgear, station-type cubicle switchgear, metal-enclosed
interrupter switchgear and low voltage power circuit breaker switchgear are specific types of
metal-enclosed power switchgear. Not all metal-enclosed power switchgear can be called
metal-clad. For example, metal-clad switchgear is a specific type of metal-enclosed power
switchgear, but not all metal-enclosed power switchgear is called metal-clad switchgear.
Figure 15. Switchgear Classification

Switchgear is also classified by voltage, as illustrated in Figure 16.
Figure 16. Switchgear Voltage Classification
Metal-Clad Switchgear (601 - 15,000 V)
Metal-clad switchgear is the most common type of switchgear found in Saudi Aramco
industrial facilities. Metal-clad switchgear is manufactured in types that can be used for either
indoor or outdoor applications. Figure 17 shows a typical indoor application of medium
voltage metal-clad switchgear that has three vertical sections. Each section contains a circuit
breaker. This particular type of switchgear uses an air-magnetic type circuit breaker. Newer
switchgear uses vacuum circuit breakers or SF6 circuit breakers. Vacuum breakers are
smaller and require less maintenance. Due to their smaller size, two vacuum circuit breakers
are typically installed in each vertical section (one above the other).
Metal-clad switchgear is typically available in voltage ratings ranging from 4.16 to 15 kV,
current ratings of 600, 1200, 2000, and 3000 amperes, and fault interrupting ratings ranging
from 75 to 1000 MVA.

Figure 17. Typical Metal-Clad Switchgear (Air-Magnetic)
Low Voltage Switchgear (Up to 600 V)
Metal-enclosed low voltage power circuit breaker switchgear is manufactured in types that
can be used for either indoor or outdoor applications. The features of metal-enclosed low
voltage power switchgear are very similar to that of metal-clad switchgear. Low voltage
switchgear has drawout circuit breakers and the same type interlocks as metal-clad
switchgear. The circuit breakers also can be placed into the connected, test, disconnected,
and withdrawn positions. Figure 18 is an illustration of typical low voltage switchgear.
Low voltage power circuit breaker switchgear is typically available for nominal system
voltages up to 600 V, current ratings ranging from 225 to 6000 A, and interrupting ratings
ranging from 22 to 130 kA. Adding current limiters (current limiting fuses) to the switchgear
increases low voltage switchgear interrupting ratings to 200 kA.

Figure 18. Typical Low Voltage Switchgear
Interrupter Switchgear (601 - 34500 V)
Metal-enclosed interrupter switchgear is also designed for both indoor and outdoor use. The
general characteristics of interrupter switchgear were described previously, in this Information
Sheet, under the heading “Switches”.
Voltage ratings for interrupter switchgear range from 4.16 to 34.5 kV and current ratings
range from 600 to 5000 amperes. The interrupter switch by itself does not have a fault
interrupting rating. The switch must use power fuses to obtain a fault interrupting rating up to
500 MVA.
Station-Type Cubicle Switchgear
Station-type cubicle switchgear is designed for either indoor or outdoor applications. Station-
type cubicle switchgear uses power circuit breakers commonly found in many Saudi Aramco
industrial facilities. For example, station-type cubicle switchgear is commonly found in
applications where circuit breakers are used to start motors rated 15,000 horsepower or higher
at 13.8 kV. This type of switchgear is also used where a large generator is connected to a
unit-transformer and switched at the generated voltage. High fault levels are available at this
type of application, requiring station-type cubicle switchgear. Generally, use of station-type
cubicle switchgear is not a cost effective design practice.

Voltage ratings for station-type cubicle switchgear range from 14.4 to 34.5 kV and current
ratings range from 1200 to 5000 amperes. Station-type cubicle switchgear also has the ability
to withstand momentary fault levels ranging from 1500 to 2500 MVA.
Station-type cubicle switchgear can be identified by the following features:
• It has stationary (non-drawout) power circuit breakers.
• The bus and connections are not insulated.
• Grounded metal barriers separate and enclose each phase of the primary circuit, which
means each phase of the main bus is in a separate or segregated enclosure.
• It contains a three-pole, group-operated switch that is interlocked with the power circuit
breaker and the front door, which isolates the circuit breakers.
• It has control wiring and accessory devices.
The following characteristics distinguish station-type cubicle switchgear from metal-clad

switchgear:
• It is impossible to withdraw the circuit breaker; it is permanently installed in the

enclosure.
• Since the circuit breaker cannot be withdrawn from the enclosure, a built-in group-
operated disconnect switch is part of the design. By operating this switch, the breaker is
isolated from the main power circuit. This group-operated switch is operated from
outside the switchgear enclosure.
• Each phase of the main bus is housed within its own grounded metal enclosure, which is
called segregated phase bus.
• Control and protection devices are not mounted on the switchgear. These devices must
be mounted on a remote relay or control panel called a duplex panel. One side of the
duplex panel has control devices and the other side is used for protective devices such as
protective relays.
Station-type cubicle switchgear must contain interlocks that prevent:
• operation of the isolating switch, when the circuit breaker is closed.
• operation of the circuit breaker, unless the isolation switch is fully open or fully closed.

• access to the circuit breaker compartment, unless the isolation switch is fully open.
The interlocks are usually part of a key interlock system known as a Kirk Key Interlock. The
switchgear equipment manufacturer designs the key system to ensure proper operation of the
equipment. There is only one key for each lock, and it is designed so that all conditions must
be met before operating the equipment. Kirk Key systems can be complex, but they are very
reliable. The operation of the key interlock system is described on the inside of the
compartment door, where the interlock system is installed.
Medium and High Voltage Circuit Breakers
A wide variety of circuit breaker designs are available for medium and high voltage systems.
The most common types are air-magnetic, vacuum, SF6, and oil. These breakers are
identified by the medium in which the main contacts interrupt the circuit. These types of
breakers are also found in metal-clad switchgear and are of a drawout design. All medium
and high voltage circuit breakers can open and clear faults up to their maximum ratings, but
they do not sense faults directly. They operate only when electrically signaled to do so by
some external means, such as control switches or protective relays. This operating scheme is
different from low voltage power circuit breaker operating schemes where the tripping
intelligence is mounted directly on or within the breaker itself.
Oil Circuit Breakers
The oil circuit breaker (OCB) is probably the most common type of circuit breaker found in
large outdoor substations. Mineral oil is used as the insulating and arc interruption medium.
On arc interruption the oil quickly extinguishes or quenches the arc. All main power
electrical components are immersed in a tank filled with mineral oil. Depending on the
breaker rating, all three phases may be in one oil-filled tank, or each phase will be in a
separate oil-filled tank. At the higher voltage rating, there may be in excess of 1000 gallons
of oil in each tank. Oil circuit breakers have an excellent history of performance. Their major
disadvantage is their use of mineral oil, which is flammable and requires periodic testing and
maintenance. OCBs are applied at voltages ranging from 34.5 to 345 kV.
Sulfur-Hexafluoride (SF6) Gas Circuit Breakers
Another type of breaker commonly used is the gas circuit breaker. The gas circuit breaker is
quickly replacing the oil circuit breaker. Sulfur-hexafluoride (SF6) is a gas with excellent
insulating and arc interrupting properties. SF6 gas is inert, non-flammable, non-toxic, and
odorless.

The contacts of an SF6 gas circuit breaker are contained within a sealed tank, in which SF6
gas is maintained at a pressure of about 75 pounds per square inch. The breaker is designed
such that when the contacts separate, there is a pressure build-up of gas around the parting
contacts. This high pressure gas sweeps away the hot arc gases, stretches, and cools the
gases, and finally extinguishes the arc. SF6 circuit breakers are commonly found at voltage
levels ranging from 34.5 to over 700 kV. SF6 breakers also are becoming more readily
available for medium voltage applications.
Vacuum Circuit Breakers
An air-magnetic circuit breaker is very large and heavy. The arc chutes are costly and can
weight up to 250 pounds. Extinguishing a powerful high voltage arc of ionized gases is very
difficult. It is much simpler to extinguish an arc in a vacuum since there are no gases to
ionize. The arc in a vacuum consists only of vaporized metal from the contacts.
A circuit breaker using vacuum interrupters or “bottles” is much simpler in design than an air-
magnetic circuit breaker. It is more compact since there are no arc chutes. The operating
mechanism is much simpler since the contacts only separate about one-half inch.
The vacuum bottle consists of a pair of contacts surrounded by a vapor-condensing shield.

The contact at one end is fixed in position and the other is connected to a flexible metallic
bellows to allow for the contact travel. The entire assembly is sealed in a vacuum-tight
enclosure. The arc is extinguished the first time the current passes zero after the contacts part.
One major concern in applying vacuum interrupters is what could occur if an interrupter lost
its vacuum and tried to interrupt a fault current. Loss of vacuum would probably destroy the
vacuum interrupter, but most manufacturers state the damage would be confined to the
interrupter. The breakers phase-to-phase and phase-to-ground insulation would prevent
further damage to the breaker.
Vacuum interrupters require very little maintenance. Contact erosion, which occurs during
each interruption, is slight, and the interrupters should last the normal life of a breaker. Since
it’s impossible to visually inspect the contacts, a method to check contact erosion is provided
by the manufacturer. Periodically checking vacuum integrity, by applying an AC high
voltage across the open contacts, is the only other maintenance requirement for the vacuum
circuit breaker interrupter.

Air-Magnetic Circuit Breakers
The most frequently used breaker for medium voltage applications is the air-magnetic
breaker. Its name comes from the fact that the contacts are in air and a magnetic field is used
to help elongate the arc and pull the arc into the arc chute. Air-magnetic circuit breakers are
often called air circuit breakers.
Air circuit breakers (ACBs) are physically quite large and are mounted on wheels to permit
movement. A typical breaker may be 3 feet wide, 6 feet high, 3.5 feet deep and weigh close
to 1500 pounds. The circuit breaker has a steel frame that supports the operating mechanism
and the current carrying parts. The size of the breaker depends on its voltage, current, and
interrupting ratings. The operating mechanism is a stored-energy mechanism.
The arc chutes or arc interrupters of ACBs must be able to handle very large amounts of
energy. The arc chutes are very large and the arc splitter plates are made of ceramic and not
metal, because metal arc chutes would melt due to the amount of energy released during arc
interruption. The arc is drawn up into the arc chute by its own magnetic field and also by a
field generated from an electromagnet built into the sides of the arc chute. This electromagnet
is called a blow-out coil. As the arc is drawn up into the arc chute, the arc is elongated,
cooled, deionized, and extinguished.
When an air circuit breaker opens under low current such as rated continuous current, there
may not be enough energy for the arc to rise up into the arc chute. To prevent this from
happening, many breakers have a built-in device called a puffer. A puffer is a piston in a
plastic tube that is connected to the breaker operating mechanism. When the breaker opens,
the piston moves and forces a puff or blast of air through a plastic tube to the area where
arcing starts, which forces the arc up into the arc chute.
Most manufacturers no longer make medium voltage air-magnetic circuit breakers. Vacuum
circuit breakers have become the standard for medium voltage applications.
Power Fuses
A fuse is a device that protects an electrical circuit by fusing (melting) open its current-
responsive element when an overcurrent (low magnitude) or short circuit current (high
magnitude) passes through it. A fuse has the following functional characteristics:
• It combines both the sensing and interrupting elements in one self-contained device.
• It is a direct acting device in that it responds to both magnitude and duration of the
current flowing.
• It normally requires separate devices, such as a disconnect switch, to make or break the
connection to an energized circuit.

• It is a single-phase device in that it only responds to de-energize the individual phase

carrying the overcurrent or fault.
• It must be replaced after operation.
Current Limiting Power Fuses (CLF)
A current limiting power fuse (CLF) limits the peak current of a short circuit, which reduces
magnetic stresses. The higher the current, the higher the magnetic stresses on the faulted
circuit. Magnetic stresses are converted to mechanical energy (magnetic forces). Also, by
limiting the current, less thermal energy is produced. Many parts of an electrical system have
both thermal and mechanical limits. By limiting the current, there is less damage to other
parts of the electrical system from both thermal and magnetic stresses, which are both related
to the current squared (I2) and the amount of time (t) the fault remains on the system.
The melting of the element of a CLF causes a high arc resistance in the fuse. Current passing
through this high arc resistance causes a high arc voltage to develop. This high arc voltage
limits the peak current. The higher the fault current, the faster the fuse operates. I2t energies
are greatly reduced by current limiting fuses. At high fault levels, a CLF can extinguish the
arc in less than a half cycle (.008 sec at 60 Hz) and usually less than a quarter cycle (.004 sec
at 60 Hz). Figure 19 shows the CLF action on a high fault current waveform. Melting time
(tm) is the time that it takes for the fuse element to melt at a certain current level. Arcing time
(ta) is the time that is between the melting time to the time that the arc is extinguished. The
total clearing time (tc) is the addition of the melting time plus the arcing time.

Figure 19. CLF Current Limiting Characteristics

Current limiting fuses are categorized as either general purpose or R-rated. Another name for
a general purpose fuse is E-rated. The letters E and R mean that the fuses are manufactured to
certain standards set for that code letter. The E-rated fuses operate over a wider range of
overcurrents than an R-rated fuse. R-rated fuses only interrupt high level fault currents.
E-Rated CLF - The E number on a CLF is the continuous current rating of the fuse. Preferred
continuous current ratings range from 0.5 to 400 amperes. The requirements for an E-rated
fuse are as follows:
• An E-rated fuse must carry its rated current continuously.
• An E-rated fuse that is rated 100 amps or less must open in less than 300 seconds at 200-
240% of its rating, and an E-rated fuse that is rated over 100 amps must open in less
than 600 seconds at 220-264% of its rating.
The interrupting ratings of E-rated current limiting power fuses are a function of the system
voltage. In general they have interrupting ratings of 50 kA RMS symmetrical and 80 kA
RMS asymmetrical (Iasy = 1.6 x Isym).
R-Rated CLFs are available in current ratings from 1.5R to 50R and in voltage ratings up to
5080 volts. Standards assign maximum continuous current ratings of 40 amperes for a 1.5R
fuse and up to 650 amperes for a 36R fuse at ambient temperatures of 400C. The R rating
typically indicates a 15-35 seconds (typically 20 sec) melting time at 100 times the R rating of
the fuse. For example, a 12R fuse opens in approximately 20 seconds at 1200 A (100 x 12A).
R-rated fuses provide short circuit protection only, and they have RMS symmetrical
interrupting ratings of 40 kA and 50 kA, and RMS asymmetrical ratings of 64 kA and 80 kA
respectively (Iasy = 1.6 x Isym).
Non-Current Limiting (Expulsion) Power Fuses

A non-current limiting power fuse is more commonly called an expulsion fuse. A non-CLF
fuse element also starts to melt in less than a half cycle, but it is unable to extinguish the arc in
a half cycle. At high currents, the arc in a non-CLF is not quickly extinguished. Because it
cannot quickly extinguish the arc, the fuse allows the short circuit current to reach its peak
value and the I2t energies are at a maximum value. Expulsion fuses are also classified as
general purpose fuses (E-rated). Preferred continuous current ratings also range from 0.5 to
400 amperes. Interrupting ratings are a function of the system voltage and type of lining.
Boric acid and horn fiber are examples of two different types of expulsion fuses. The
asymmetrical factor for expulsion fuses is also 1.6 (Iasy = 1.6 x Isym).
E-Rated Power Fuse Time/Current Characteristics
Figure 20 illustrates the time/current (T/C) characteristics of current limiting E-rated type
power fuses. Figure 20 also illustrates an arcing time (ta = tc - tm) of approximately 0.6
seconds (1.1 - 0.5) for a 300 A low level fault.

Figure 20. CLF T/C Characteristic Curves

Figure 21 illustrates the T/C characteristics of expulsion (non-CLF) type fuses. Figure 21 also
illustrates arcing time (ta = tc - tm) of approximately 0.18 seconds (.30 - .12) for a 300 A low
level fault. Compared to Figure 20, it is obvious that the expulsion fuse is a much better low
level fault (overload magnitude) fuse.
Figure 21. Non-CLF T/C Characteristic Curves

Figure 22 illustrates the comparison of CLF versus non-CLF T/C characteristic curves. As
can be seen in Figure 22, at overload current magnitudes (e.g., 700 A), the expulsion fuse
clears faster (t1 < t2), and at fault current magnitudes (e.g., 7000 A), the CLF is faster (0.01
seconds or less).
Figure 22. Comparison of CLF and Non-CLF T/C Characteristic Curves

Electronic Power Fuses
Electronic power fuses are a relatively new class of medium voltage power fuse. Electronic
power fuses, such as the S & C Electric Company Fault Fiter Electronic Power Fuse (Figure
23), are equipped with inverse-curve-type control modules ideally suited for load feeder
protection and coordination in industrial commercial, institutional, and utility substations.
Electronic power fuses provide (1) 600 A continuous current ratings that are frequently
required on circuits serving multiple loads, (2) 40 kA interrupting ratings that are required for
large industrial applications, and (3) the unique T/C characteristics required to coordinate with
source-side protective equipment and load-side fuses that provide dedicated protection for
transformers.
Figure 23. S & C Electronic Power Fuse

The S & C power electronic fuse consists of four components that include a mounting
bracket, holder, control module, and interrupting module (Figure 23). The mounting bracket
incorporates heavy-duty construction to provide sure guidance for the holder during opening
and closing operations, and to resist the substantial magnetic forces resulting from high
current faults. The control module provides the current sensing and time/current
characteristics for the fuse, as well as the energy to initiate operation of the interrupting
module in the event of a fault. The interrupting module carries load current continuously and
operates to interrupt a fault after receiving a trip signal from the control module. Following a
fault-clearing operation, the interrupting module is replaced. The control module is
unaffected by fuse operation and is reused.
The electronic control module consists of an integral toroidal current transformer (CT) which
provides line-current sensing and control power for the electronic circuitry. The CT also
provides the energy to operate the interrupting module in the event of a fault. Electrical
output from the CT is processed by the electronics located inside the factory-sealed cast-
aluminum control module housing, which serves both as a path for continuous current and as
a Faraday cage to shield sensing circuits against interference from external electric fields.
When a fault occurs, the electronics within the control module initiate a “trip” signal in
accordance with electronically derived time/current characteristics. The signal to “trip” is
delivered to the interrupting module through a low resistance gold-plated contact.
The interrupting module and control module are mechanically attached to one another by
means of a threaded connection. Trouble-free, operator-independent electrical connection of
the control module and the interrupting module is assured by means of a louvered ring-type
sliding contact, which is of the same type of contact that is widely used in circuit breakers and
elbow connectors. Complete electrical coupling is automatically achieved when the two
modules are joined at the threaded connection.
The interrupting module includes a specially designed main current section centrally
positioned within the interrupting module. The main current section carries load current
under normal operating conditions and is rapidly opened, in the event of a fault, by the action
of a gas-generating power cartridge and associated insulating piston. After the main current
section is opened, fault current is shunted into the circuit interrupting section and the coaxially
wound fusible elements.

The circuit interrupting section, which is electrically in parallel with the main current section,
consists of helically wound copper ribbon fusible elements embedded in highly refined silica
sand. Unlike conventional power fuses, the fusible elements in the interrupting module do not
carry load current and do not determine the T/C characteristics of the fuse (T/C characteristics
are provided by the control module.) Consequently, the S & C electronic power fuse is not
subject to the unpredictable protection actions that can be introduced to conventional current
limiting fuses, for example, when the current limiting fusible elements are subjected to load
cycling or repeated current surges that may alter the T/C characteristics of the element.
Figures 20 and 21 showed the T/C characteristics of conventional power fuses; Figure 24
illustrates the electronically derived T/C characteristic curves of S & C electronic power
fuses. Because of the electronic control module, electronic power fuses are typically better
coordination devices (fuses) than either current limiting or expulsion-type power fuses.
Figure 24. T/C Characteristic Curves of S & C

Electronic Power Fuses

Instrument Transformers
Instrument transformers are used both to protect personnel and apparatus from high voltage
and to allow reasonable insulation levels and current-carrying capacity in relays, meters, and
instruments. Instrument transformer performance is critical in protective relaying, because
the relays are only as accurate as the instrument transformers. In the United States, standard
instrument transformers and relays are rated at 5 amperes and/or 120 volts, 60 Hz.
Where the relays operate only on current or voltage magnitude, the relative direction of
current flow in the transformer windings is not important. Relative direction (and, therefore,
polarity) must be known, however, where the relays compare the sum or difference of two
currents or the interactions of several currents or voltages. The polarity is usually marked on
the instrument transformer but it can be determined if necessary (Figure 25).
Figure 25. Instrument Transformer Diagram

Current Transformers (CTs)

The major criteria for selecting a current transformer ratio are the continuous current ratings
of the connected equipment (relays, auxiliary current transformers, instruments, etc.) and of
the secondary winding of the current transformer itself. In practice, with load current
normally flowing through the phase relays or devices, the ratio is selected so that the
secondary output is around 5 amperes at maximum primary load current. Where delta-
connected current transformers are used, the square root of three ( 3 ) factor must be
included.
Although the performance required of current transformers varies with the relay application,
high quality transformers should always be used. The better quality transformers reduce
application problems, present fewer hazards, and generally provide better relaying. The
quality of the current transformers is most critical for differential schemes, where the
performance of all the transformers must match. In differential schemes, relay performance is
a function of the accuracy of reproduction, not only at load currents, but at all fault current
levels as well.
Voltage Transformers (VTs)
Voltage transformers (formerly called potential transformers) are selected according to two
criteria: the system voltage level and the basic impulse insulation level required by the
system on which they are to be used. Two nominal secondary line-to-line voltages of 115 and
120 volts are allowed for voltage transformers and the corresponding line-to-neutral values
are 115/ 3 and 120/ 3 . The applicable voltage depends on the primary voltage rating as
listed in ANSI Standard C57.13.
Most protective relays have standard voltage ratings of 120 volts or 69 volts, depending on
whether they are to be connected line-to-line (120 V) or line-to-neutral (69 V).
Control House
Many industrial substations have a control house which is an air-conditioned building that
houses, and/or environmentally protects, the secondary switchgear, batteries for the DC
control system, metering equipment, and protective relays.
Protective Relays
IEEE Standard 100-1984 defines a protective relay as “a relay whose function is to detect
defective lines or apparatus or other power system conditions of an abnormal or dangerous
nature and to initiate appropriate control circuit action.”
Protective relays for power systems are made up of one or more fault-detecting or decision
units, along with any necessary logic networks and auxiliary units. Because a number of
these fault-detecting or decision units are used in a variety of relays, they are called basic

units. Basic units fall into three categories: electromechanical units, sequence networks, and
solid-state units.
Generally, input to all the protective relays is either a voltage, a current, or both voltage and
current. Instrument transformers (current and voltage transformers) supply the input to the
protective relays. When a protective relay operates (Figures 26 and 27), it either closes or
opens a set of contacts, which cause the circuit breaker to trip. The most common relay
operating characteristics are time-delay functions and instantaneous functions.
Relay panels in control houses differ in each substation. In many instances, relay panels are
often combined with the control functions (panels) to form a duplex panel, as illustrated in
Figure 28.
DC Control System Battery
DC control power is typically supplied by a storage battery (Figure 29). The capacity of a
substation battery is specified in ampere-hours. A typical rating may be 120 ampere-hours,
which means that the battery could supply 15 amperes of power at rated voltage for 8 hours,
or 20 amperes for 6 hours, etc. A battery charger is also required to keep the battery in a
fully-charged state. Similar to the battery itself, the battery charger is also sized for the
battery as well as any steady state loads that exist.

Figure 26. Battery Trip Circuit
Figure 27. Capacitive Trip Circuit

Figure 28. Duplex Relay and Control Panel

Figure 29. Typical Substation Battery
Metering and Instrument Equipment
Instruments and meters are used to indicate or measure electrical quantities. An instrument is
a device that is used for measuring the value of a quantity under observation. The two most
common types of instruments found in Saudi Aramco facilities measure voltage and current.
Other instruments include wattmeters, varmeters, and power factor meters.
A meter measures and registers a quantity with respect to time. A common meter typically
found in the Saudi Aramco power system is a kilowatt-hour meter. Instruments, such as
ammeters and voltmeters, are often called “meters” but technically this is inaccurate.
The meters and instruments are mounted on the exterior front panel of a section of switchgear
and are called switchboard instruments (Figure 28a). The type of metering and
instrumentation that is used depends on plant requirements.

Air-Conditioning Equipment
Saudi Aramco standards specify that each substation control house have 100% redundant
(two) air-conditioning systems. Each air-conditioning system must be capable of maintaining
the temperature at 250C for occupied substations and 350C for unoccupied substations.
Miscellaneous Components
Steel Structures
An outdoor substation often has several galvanized steel structures (Figure 30) that provide
support for the main bus, switches, insulators, lightning arrestors, etc.
Insulators
The insulators provide electrical isolation between the steel structures and the energized bus.
The number and type of insulators used in a substation depend on the system voltage. Figure
30 also illustrates application of string and standoff-type insulators.
Surge or Lightning Arrestors
Surge arrestors or lightning arrestors are used to prevent damage to the substation equipment
from lightning strokes and other high voltage surges. The arrestors are connected from each
phase conductor to the substation grounding system and are located as close as possible to the
transformer. The transformer is the most likely piece of equipment to be damaged by a
sudden voltage surge. Both Figures 30 and 31 show substation application of surge or
lightning arrestors.

Figure 30. Outdoor Substation with Dead-End Steel Structure

Figure 31. Substation Surge or Lightning Arrestor Applications

Grounding System
ANSI/IEEE Standard 80-1986 formally defines the physical elements involved in a grounding
system as follows:
• Ground Electrode - A conductor that is imbedded in the earth and used for collecting
ground current from or dissipating ground current into the earth.
• Grounding Grid - A system of horizontal ground electrodes that consists of a number of

interconnected, bare conductors buried in the earth providing a common ground for
electrical devices or metallic structures, usually in one specific location.
• Ground Mat - A solid metallic plate or a system of closely spaced bare conductors that
are connected to and often placed in shallow depths above a ground grid or elsewhere at
the earth’s surface.
• Grounding System - Comprises all interconnected grounding facilities in a specific area.
In general practice the grounding system takes the form of a grid (Figure 32) of horizontally
buried conductors, that is supplemented by a number of vertical ground rods connected to the
grid. A typical grid system for a substation may include AWG No. 4/0 bare copper
conductors buried 0.3 - 0.5 m (12 - 17 in) below grade, spaced 3 - 7 m (10 - 20 ft) apart in a
grid pattern. Ground rods might be at the grid corners and at major equipment points. The
perimeter of the loop would enclose as much area as possible and would be extended 1 meter
beyond the substation fence and be connected to the metallic fence post every 15 meters (50
ft).

Figure 32. Typical Ground Grid System

ACSR/AW Aluminum Conductor Steel Reinforced/Aluminum Weld
air-magnetic breaker A type of medium voltage circuit breaker that has its contacts in
air. A powerful electromagnet built into the arc chutes aids in
extinguishing the arc.
ANSI American National Standards Institute
arc chute A structure that has a confined space or passage way, usually
lined with arc-resisting material, into or through which an arc is
directed to be extinguished.
arcing contacts The contacts of a switching device where all arcing takes place
during operation.
arcing time (ta) The amount of time that it takes a fuse to suppress an arc.
basic impulse level A factory test that shows how well an insulation
(BIL) system can withstand a high voltage surge.
cage (Faraday) A system of conductors forming an essentially continuous

conducting mesh or network over the object protected and
including any conductors necessary for interconnection to the
object protected and an adequate ground.
capacitive trip An auxiliary device that stores energy to provide power to trip a
circuit breaker after AC power is lost.
(a) cell Another term for the compartment where a drawout circuit
breaker is placed inside switchgear. A cell is also called a
cubicle.
circuit breaker A mechanical switching device that is capable of making,

carrying, and breaking currents under normal and abnormal
circuit conditions.
clearing time (tc) The amount of time that it takes a fuse to interrupt a circuit at a
certain current level.
CLF Current Limiting Fuse
continuous current The amount of current that a device can allow to pass

rating through it without causing excessively high

temperature or equipment failure.
control power Power used for control of main power equipment. It is used to
trip and close breakers and operate indicating lights and relays.
CT Current Transformer
cubicle Another term for the compartment where a drawout circuit

breaker is placed inside switchgear. A cubicle is also called a
cell.
current limiting fuse A type of fuse that interrupts a fault current, but limits it to some
value usually well below the peak current and operates in one-
half cycle (.008 sec) or less.
duplex panel A type of relay and control panel that is found in main
substations. One side of the panel is for control functions and
the other side is for relay protection functions. The two panels
fit back-to-back with an aisle in the middle.
element The piece or pieces inside a fuse that melt to interrupt a current.
During normal operation, the fuse element carries the current
flowing through the fuse.
(to) extinguish To put out the arc that occurs when a fuse operates.
frame size A term that describes the maximum continuous current rating in
amperes of a circuit breaker.
fuse An electrical device that is designed to interrupt a circuit on an

overload or fault.
ground electrode A conductor that is embedded in the earth and used for collecting
ground current from, or dissipating ground current into the earth.
grounding electrode A conductor that is sized to provide an electrical path

conductor consistent with the objectives of equipment
grounding, between metal enclosures in the
grounding path to earth.
grounding grid A system of horizontal ground electrodes that consist of a

number of interconnected bare conductors buried in the earth,

providing a common ground for electrical devices or metallic

structures, and usually located in one specific area.
grounding system A system that comprises all interconnected grounding facilities

in a specific area.
ground mat A solid metallic plate or a system of closely spaced bare

conductors that are connected to, and that is often placed in
shallow depths above a ground grid or elsewhere at the earth
surface.
high voltage A switchgear rating that is between 15 kV and

switchgear 34.5 kV.
instruments A term that describes a device that is used to measure or display

a quantity under observation. Examples of instruments include a
voltmeter or an ammeter.
interlock A method or device that prevents someone from operating a

breaker or other system component under unsafe conditions.
interrupter An element that is designed to interrupt specified currents under

specified conditions.
interrupter switch A type of switch that is designed to interrupt load current and
some level of fault current. The switch can be fused or non-
fused. An interrupter switch is sometimes called a load-break
switch.
inverse time-current A term that is used to describe a characteristic curve for a fuse or
protective relay. It indicates that as the current increases the
time decreases.
isolating switch A type of switch that is used to isolate a circuit or a piece of

equipment. The isolating switch has no load-break or short
circuit interrupting rating.
lightning arrestor A surge protection device that operates on a surge voltage

caused by lightning or switching. The lightning arrestor operates
and shunts the surge to ground.
lightning mast A structure in an outdoor substation that is used to protect the

substation from direct lightning strokes.

load-break switch A type of switch that is designed to interrupt load current and
some level of fault current. The load-break switch can be fused
or non-fused. A load-break switch is normally called an
interrupter switch.
low voltage A switchgear rating that is less than or equal to 600

switchgear volts.
main contacts The contacts of a switching device that carry the load current.
maximum design The highest voltage at which a device is designed

voltage to operate.
medium voltage A switchgear rating that is between 601 and 15,000

switchgear volts.
melting time (tm) The amount of time that it takes a fuse element to melt at a
certain level of current.
metal-enclosed A general term that is used to describe a metal

power switchgear enclosure that contains electrical components.
Usually abbreviated as “switchgear”.
meter A device that is used to measure an electrical quantity. An

example would be a kilowatt-hour meter or a power factor meter.
momentary current The current that is flowing in a device at the major peak of the
maximum cycle, as determined from the envelope of the current
wave.
momentary rating The ability of a switching device to withstand the mechanical

forces that occur during the first cycle of a short circuit.
nominal system A nominal value assigned that designates a system

voltage of a given voltage class.
non-current limiting A type of fuse that does not limit the peak fault
fuse current.
oil circuit breaker A type of circuit breaker that uses mineral oil as an insulating
and arc interrupting medium.

opening time The amount of time that it takes for a switching device to open.
Opening time is usually measured in cycles. One cycle equals
1/60 of a second (0.0167 seconds).
primary selective A type of substation bus configuration that feeds two

transformers from the same bus.
protective relay A special relay that is designed to sense abnormal conditions in

an electrical system.
quick make - A type of action of a switch mechanism, which means

quick break that the contacts will open and close very quickly.
radial system A type of substation bus configuration that has one incoming
feed where all loads are distributed from one bus.
reliability The ability of a substation or a piece of electrical equipment to

operate without failure.
safety switch A type of low voltage switch that has load-break capability.
secondary selective A type of substation bus configuration that allows flexibility on a

secondary bus system to feed all loads from one transformer by
closing of a normally open (N.O.) tie breaker.
short-time rating A rating for low voltage power circuit breakers and medium
voltage breakers that describes the breaker’s ability to withstand
a fault current for a period of time. If a breaker does not have an
instantaneous trip unit, it must have a short-time rating.
substation A group of electrical equipment that has a power transformer

rated 501 kVA or larger.
sulphur-hexafluoride A type of circuit breaker that uses sulfur-hexafloride

circuit breaker (SF6) gas (SF6) as an insulating and arc extinguishing
medium.
switchgear An abbreviated term for metal-enclosed power switchgear.
T/C Time/Current

time/current curves Curves that show the operating characteristics of a protective

device. The vertical axis shows time and the horizontal axis
shows current. The curves are usually plotted on semi-log paper.
unit substation A coordinated packaged substation that has a high

(low voltage) voltage interrupting switch, a transformer, and
switchgear.
vacuum circuit A specific type of medium voltage circuit breaker tha

breaker is designed to interrupt the arc inside a container that is under a
vacuum. The vacuum limits ionization of gases and makes the
circuit breaker lighter and more compact.

Figure 33. Fuse T/C Curves, Problems 11 and 12


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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Industrial Facility Substations:

Chapter : Electrical For additional information on this subject, contact

FUNCTIONS OF A SUBSTATION ...................................................................... 2

TYPES OF SUBSTATION CIRCUIT ARRANGEMENTS.................................... 6

RADIAL SYSTEMS .......................................................................................... 6

MAJOR SUBSTATION COMPONENTS............................................................. 15

Saudi Aramco DeskTop Standards

Saudi Aramco DeskTop Standards

E-Rated Power Fuse Time/Current Characteristics......................... 35

Saudi Aramco DeskTop Standards

• Generating plant substation

• Large, medium, and small industrial substations

Saudi Aramco DeskTop Standards 1

Figure 1. Electrical Power System

Saudi Aramco DeskTop Standards 2

Figure 2 is a one-line diagram illustrating the major functional components of a substation.

Figure 2. Substation Functions

Saudi Aramco DeskTop Standards 3

System protection is accomplished by means of fuses, circuit breakers, lightning arrestors,

Saudi Aramco DeskTop Standards 4

• Bus configuration and circuitry

• Equipment and incoming line redundancies

• Quality of the equipment in the substation

Saudi Aramco DeskTop Standards 5

TYPES OF SUBSTATION CIRCUIT ARRANGEMENTS

Simple Radial System

Expanded Radial System

Saudi Aramco DeskTop Standards 6

Figure 3. Radial Systems

Saudi Aramco DeskTop Standards 7

Primary Loop System

Secondary Loop System

Primary Selective System

Saudi Aramco DeskTop Standards 8

Figure 4. Loop Systems

Saudi Aramco DeskTop Standards 9

Figure 5. Primary Selective System

Saudi Aramco DeskTop Standards 10

Secondary Selective System

If pairs of unit substations transformers (double-ended substation configuration) are

Combined Selective System

Saudi Aramco DeskTop Standards 11

Figure 6. Secondary Selective Systems

Saudi Aramco DeskTop Standards 12

Figure 7. Combined Selective System

Saudi Aramco DeskTop Standards 13

Figure 8. Alternate Combined Selective System

Saudi Aramco DeskTop Standards 14

MAJOR SUBSTATION COMPONENTS

• Open Bus (Rigid)

• Non-Rigid or Strain Bus

Open Bus (Rigid)

Non-Rigid or Strain Bus

Saudi Aramco DeskTop Standards 15

Figure 9. Bus Arrangement North-to-South (Top-View)

Figure 10. Bus Arrangement East-to-West (Top View)

Saudi Aramco DeskTop Standards 16