INSTALLATION OF GROUNDING GRID AND ERECTION/INSTALLATION OF SUBSTATION EQUIPMENT FOR A 2X30/40MVA, 132/33KV SUBSTATION AT OGOJA, CROSS RIVER STATE.

CHAPTER ONE 1.0 INTRODUCTION

This technical report covers the installation of grounding grid and erection/installation of substation equipment for a 2x30/40MVA, 132/33KV AC transmission substation, located at Ogoja in Cross River state. Safety and reliability are the two major concerns in the operation and design of an electrical power system. These concerns also pertain to the design of substations. To ensure that substations are safe and reliable, the substation must have a properly designed grounding system. The two main design goals to be achieved by any substation ground system under both normal and fault conditions are: 1. To provide means to dissipate electric currents into the earth without exceeding any operating and equipment limits 2. To assure that a person in the vicinity of grounded facilities is not exposed to the danger of critical electric shock. In order for the substation to be functional, the substation equipment must be installed in accordance with the manufacturers specifications. This report details the installation of most outdoor substation equipment and also the installation of grounding grid. 1.1 SCOPE OF WORK The scope of the work for the project included the following: Erection/installation of substation equipment Installation of the grounding grid system

 Testing of the grounding grid effectiveness

1.2 OBJECTIVE OF THE TECHNICAL REORT The objective of this technical report is to present details of the installation of a safe grounding grid system and erection of equipment for an AC substation. This technical report is basically the product of my post graduation field experience in the area of AC substation grounding grid installation and installation of substation equipment.

CHAPTER TWO 2.0 WORKING EXPERIENCE WITH DATE AND POSITION HELD Below is summary of the projects that i was involved in during the period of my post graduate work experiences. Aydemir Engineering Nig. Ltd: 2013 (2x30/40 MVA 132/33KV Electromechanical/ Instrumentation work, cross River) Site Engineer. RESPONSIBILITIES Erection of electromechanical equipment which included Erection of 2 nos. 30/40MVA power transformer Erection of 26 nos. 145KV & 13 nos. 36KVcurrent transformer Erection of 12 nos. 145KV & 13 nos. 36KV capacitive voltage transformers Erection of 6 nos. 145KV & 9 nos. 36KV circuit breaker Erection of 18 nos. 120KV surge arrester

 Erection of 36 nos. 145KV & 26 nos. 36KV disconnect switch Erection of 12 nos. 145KV semi-pantogragh Erection of 2 nos. 34.5/0.415KV station service transformer Erection of 2 nos. 34.5KV earthing reactor transformer Power stream Nig Ltd: May-August, 2012 (2x 30/40MVA 132/33KV substation grounding grid system at Ogoja). Site Engineer RESPONSIBILITIES My tasks as the supervising Engineer were to ensure the following: That the grounding grid trenches were excavated according to specifications Laying f 120mm2 copper conductor in the trenches to form the grounding grid Installation of forty (40), 2.6m ground rods round the switchyard perimeter Termination of the grounding grid to the ground rods Termination of the substation equipment structures to the grounding grid with 70mm2 copper conductor Interconnection of the main grounding grid with 120mm-120mm H-type clamps and Red clamps with hydraulic crimping machine Connection of the switchyard fence to the main grounding grid Testing of the completed grid grounding resistance with earth resistance tester. POWER STREAM NIG. LTD

October, 2009 July, 2010 (Rehabilitation of 33/11KV substation at three Arm Zone, Abuja) Electrical Technician RESPONSIBILITIES Termination of 11/33KV panels Installation of circuit breakers and relays Installation of supervisory control and data acquisition (SCADA) equipment. Installation of solar panel modules

CHAPTER THREE DETAILS OF JOB DONE Installation of Grounding Grid and Erection of Equipment for 2 x 30/40 MVA, 132/33 KV AC Substation. 3.0 BRIEF SCOPE OF WORK This technical report encompasses the installation of grounding grid and erection of equipment for 2x30/40MVA, 132/33KV AC substation located at Ogoja, Cross River state. The scope of the grounding grid installation was done in accordance with the grounding grid design specifications/drawings, using convenient equipment, machinery and method to handle the components. Also, the installation of the equipment was carried out in accordance with the manufacturers instructions and the substation design. 3.1 Construction of the Grounding System

The method of construction, or combination of methods chosen, depends on a number of factors, such as size of a grid, type of soil, size of conductor, depth

of burial, availability of equipment, cost of labour, and any physical or safety restrictions due to nearby existing structures or energized equipment. There are two commonly employed methods to install the ground grid. These are the trench method and the cable plowing method. Both of these methods employ machines. Where these machines are not employed due to lack of space to move them or small size of the job site, the ground grid is installed by hand digging. In this project, the hand digging method was employed. 3.2 Ground Grid ConstructionHand Digging Method

Flags were staked on the grid perimeter along two sides to identify the spacing between parallel conductors. These markers also served as a guide for the labourers engaged in the excavation. These trenches were dug to the specified burial depth of 0.8m.The grounding conductors were then installed in these trenches. 3.3 Work Description For The Grid Installation

A. Marking out and Excavation of grid trench with a width of 200mm and burial depth of 800mm. i. ii. Horizontal Trench of 99m x 22 x .2m x .8m Vertical Trench of 150m x 15 x .2m x .8m

B. Back filling and compacting of trench. i. ii. Horizontal Trench of 99m x 22 x .2m x .8m Vertical Trench of 150m x 15 x .2m x .8m

C. Ground grid 120mm2 Copper conductor Laying (150m x 15 for Vertical runs and 99m x 22 for Horizontal runs). D. Conductor connection at point of intersection: This was done using the Hydraulic Crimping tool and 19mm spanners. E. Laying and Connection of upriser grounding conductor for equipment connection to grid with 70mm2 Copper conductor and 90mm2 Copper bars: This was done using the Crimping tool.

F. Earth Rod Installation i. Driving of forty (40) nos. Ground rods into the ground with sledge hammer and termination of the ground rods to the grounding grid with connectors/lugs. Construction of four (4) nos. concrete ground inspection chambers.

ii.

The erection was performed in accordance with the construction drawings using convenient equipment, machinery and method to handle the components including the following: - The conductors were placed at the bottom of trenches and terminated at the intersection of the vertical and horizontal conductor using Red and H clamps. - Tap conductor were terminated to the grid as well as the ground rods. - Tap conductors were used to connect all the switchyard equipment and structure. - Disconnect switches operating handle or wheel were properly grounded. - Cable metal trays and conduits shall be grounded at various points along the way. - The fence post shall be connected to the grounding grid as per construction drawings. - The incoming transmission lines counterpoise shall be connected to the grounding grid. - The substation gate shall be connected to the grounding grid. - The grounding grid extended inside the control building to connect the various panels grounding bus. - The telecommunication equipment were grounded with insulated conductors to a common point to avoid circulating current.

After the installation of the grounding grid, a comprehensive earth resistance test was performed to measure from a remote point the overall resistance of the grid. According to the client, the desired resistance value was at most 1 . After test, the values of earth resistances gotten at the four earth inspection chambers were: 0.3 , 0.3 , 0.35 0.32 Figure 1 below depicts the grounding grid layout showing the equipment foundation and the cable uprisers for equipment/structure termination.

3.4 EREECTION AND INSTALLATION OF SWITCHYARD EQUIPMENT The erection and installation of the following substation equipment were performed. 1.1 POWER TRANSFORMER

The power transformer specifications are: - transformers 132/33 kV of 40/50/60 MVA with ONAN/ONAF cooling The erection and installation was performed in compliance with the manufacturers instruction manuals. The transformer was made by CG Power Systems Transformer division (T3). A business unit of Crompton Greaves Ltd. The entire erection of the transformer included the following: a) Erection of components (not limitative): - Bushings and connection to windings; - Conservator with support; - Header top & bottom; - Radiators, valves and fans; - Oil pipes, valves and filters; - Relays and instruments; - Cooling fans; - Intermediate headers; - Cooler pipe top; - Breather pipes work; - Buchholz relay; - OLTC oil surge relay;

Silica gel breather

b) Test, filtering and filling with oil up to cover and under vacuum. An oil sample shall be taken and tested from each individual container to insure that oil is suitable prior to filling. c) Instruments and relays tests. d) Installation of surge arresters. e) Connection to grounding grid. f) Connection of bushings to the busses. g) Connection of control cables to control cabinet terminal blocks. 1.2 Specialized Tools

The specialized tools used were: - Oil treatment plant with vacuum pump, heaters with suitable capacity and accessories. - Dielectric oil test (IEC 60156) and dew point instruments. - Tank or sack (2000 litres) for storage of oil. - Dry air or nitrogen pressurized bottles or dry air machine. - Megger test instrument. 1.3 CIRCUIT BREAKERS

The circuit breakers were of the live tank free standing (designed with SF6 for the 132KV and vacuum for the 33kV) interrupting medium, mechanical spring loaded mechanism for each phase or the three phases. Where there three single phase mechanisms, a central control cabinet was installed on the middle phase pedestal support of the circuit breaker. The erection and installation was performed in compliance with the manufacturers

instruction manuals. Convenient equipment, machinery and method to handle the components of the circuit breakers. The entire erection of the Circuit Breaker included the following: a) Assembly, mounting and leveling of pedestals of each pole. b) Lifting with nylon slings of porcelain element and assembly on the pedestals. c) Installation of mechanisms and central control cabinet. d) Filling with SF6 gas and verification for leaks with detection instrument. e) Connection to grounding grid. f) Connection of control cables to each mechanism and central control cabinet. 1.4 ERECTION OF DISCONNECT SWITCHES

The disconnect switches were of the Two-Column Rotary Disconnector Type SGF and the pantograph type disconnector with and without grounding blade with manual/electric operation (manual operation for 33kV only). The erection and installation was performed in compliance with the manufacturers instruction manuals. Convenient equipment, machinery and method to handle the components of the switches. The entire erection of the switches included the following: a) Assembly, installation and leveling of pedestals and structure support. b) The center line of semi-pantograph pedestals, using a single mechanism for all three poles shall be carefully checked and position adjusted to insure easy installation of linkage. c) Installation of mechanisms.

d) Lifting and positioning of insulators with nylon slings. e) Lifting and installation of active parts and linkage. a) Adjustment of linkage and active parts for perfect fit at closure and simultaneous three poles operation. The center break switch arms shall be perfectly aligned. b) Connection to grounding grid. c) Connection of control cables. d) When there are three mechanisms, a central control cabinet shall be installed. e) Careful adjustment of the limit switches shall be performed to avoid the mechanism from pushing the arms of the switch beyond the desired mechanical position. 1.5 SURGE ARRESTERS Surge arresters were mounted on the equipment support structure and on the MV gantry structures. The erection and installation was performed in compliance with the manufacturers instruction manuals. Convenient equipment, machinery and method to handle the components of the circuit breakers. The entire erection of the surge arresters included the following: - The surge arresters were lifted with nylon slings and mounted on the equipment support structures and gantries. - The surge counters were mounted at eye level not exceeding 1.5 m from foundation base. - The surge arresters were then grounded to the grounding grid. 1.6 INSTRUMENT TRANSFORMERS

The current transformers were mounted side by side from the circuit breaker while the voltage transformers were connected directly to the line feeders, feeders bus and to the main substation busses. The line feeders capacitive voltage transformers were used for installation of line traps and connection of power line carrier equipment. Convenient equipment, machinery and method to handle the components of the circuit breakers. The entire erection of the instrument transformer included the following: - The instrument transformer was lifted with nylon slings and placed on the equipment support structures and bolted to it. Two wave traps were mounted on the Capacitive Voltage transformer head for each transmission line feeder. - The instrument transformers were effectively bonded to the grounding grid.