Professional Documents
Culture Documents
Substation Construction Manual
Substation Construction Manual
Substation Construction Manual
5.
6.
7. 8.
9.
10. ENVIRONMENT..........................................................................................................9
10.1 10.2 10.3 10.4 Noise............................................................................................................................... 9 Oil Handling .................................................................................................................... 9 SF6 Gas Handling........................................................................................................... 9 Erosion Control and Drainage......................................................................................... 9
11.5 Safe Entry into Substations........................................................................................... 11 11.5.1 Personal Protective Equipment (PPE) 11 11.6 Performing Civil Work ................................................................................................... 12 11.6.1 Hot Works 12 11.6.2 Scaffold Certificate 12 11.6.3 Confined Space 12 11.6.4 Daily Task Risk Management Plan (DTRMP) 12 11.6.5 Safety Observers 12 11.6.6 Exclusion Zones 13 11.6.7 Authorised Person 13 11.6.8 Demolition 13 11.6.9 Asbestos 13 11.6.10 Star Pickets 13 11.6.11 00 Gloves 13 11.7 Pre-Start Meeting.......................................................................................................... 13 11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 11.16 11.17 11.18 11.19 11.20 11.21 11.22 11.23 11.24 11.25 11.26 11.27 Site Inductions .............................................................................................................. 13 Construction Signage.................................................................................................... 13 Incident Reporting and Emergency Contacts ............................................................... 14 Construction Barriers and Builders Area....................................................................... 14 Geotechnical Report and Survey .................................................................................. 14 Design........................................................................................................................... 14 As Constructed Drawings............................................................................................ 14 Earthworks .................................................................................................................... 14 Electrical Conduits, Cable Ducts and Earthing ............................................................. 15 Concrete Works ............................................................................................................ 15 Transformer and Regulator Bund Walls and Oil Interceptor Trap................................. 15 Stormwater Drainage Works......................................................................................... 15 Water and Sewer Supply .............................................................................................. 15 Roadworks .................................................................................................................... 15 Structural Steel ............................................................................................................. 15 Concrete Poles, Towers, Landing Spans and Overhead Lines .................................... 15 Concrete Masonry......................................................................................................... 15 Security Fences ............................................................................................................ 15 Switchyard Surfacing .................................................................................................... 15 Landscaping.................................................................................................................. 16
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
13. EARTHING................................................................................................................23
13.1 Main Earth Grid............................................................................................................. 23 13.1.1 Work in Energised Substations 23 13.2 Support Structures, Equipment, Cable Trench Covers ................................................. 24 13.3 13.4 Panels and Building Equipment .................................................................................... 25 Cable Screens .............................................................................................................. 25
14.5 LV Cabling, Secondary Wiring and Terminals .............................................................. 27 14.5.1 Power 27 14.5.2 Control 27 14.5.3 Fibre 28
15. MISCELLANEOUS....................................................................................................29
15.1 15.2 15.3 Auxiliary AC Supplies.................................................................................................... 29 DC Supply Systems ...................................................................................................... 29 Lighting ......................................................................................................................... 30
15.4 Nameplates, Signage, Labelling ................................................................................... 30 15.4.1 General Requirements 30 15.4.2 Rating Plates, Nameplates and Operational Signs 30 15.4.3 Labels 31 15.4.4 Safety Signs 31
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
2. RESPONSIBILITIES
Executive General Manager Operations is the Process Owner responsible for approving this Manual. Manager Engineering Services is responsible for maintaining this Manual. Substation Engineering Manager is the Subject Matter Expert (SME) for the content this Manual.
4. REFERENCES
4.1 Ergon Energy Controlled Documents BS001404R152. Inspect Insulated Tools Before Use (Field Instruction) BS001405M100. Request for Authorisation Letter (Training Material) BS001405R100. Authorised Person (Quick Reference Guide) BS001409F101. Confined Space Entry Permit (Form) BS001409F104. Hot Work Permit (Form) BS001409R104. Hot Work (Field Instruction) BS001409R113. Asbestos Management Plan (Reference) BS001409R120. Contractor Asbestos Related Work or Asbestos Removal Work (Reference) CS000501R110. Field/Workshop Personal Protective Equipment (Reference) ES000704R100. Single Incident Management Framework (Reference)
Check this is the latest version before use. Page 1 of 33 Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
SS-1-9.3. Substation Signage (Substation Design Standard Intranet) SS-1-5.2. AC Supplies (Substation Design Standard Intranet) SS-1-4.4. Cables and Cabling (Substation Design Standard Intranet) SS-2-4.1. Metering (Substation Design Standard Intranet) SS-1-7.1. Substation Earthing (Substation Design Standard Intranet)
Check this is the latest version before use. Page 2 of 33 Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
AS1111-1980 ISO Metric Hexagon Commercial Bolts and Screws AS1112-1980 ISO Metric Hexagon Nuts, Including Thin Nuts, Slotted Nuts and Castle Nuts AS1214-1983 Hot-Dip Galvanised Coatings on Threaded Fasteners (ISO Metric Coarse Thread Series) AS2067 Switchgear Assemblies and Ancillary Equipment for Alternative Voltages Above 1kV AS2601-2001 The Demolition of Structures AS2395-1980 Terminals for Switchgear Assemblies for Alternating Voltages Above 1kV AS3000:2007 Standard for Wiring Rules AS5000.1:2005 Standard for Electric Cables Polymeric Insulated For Working Voltages up to and Including 0.6/1 (1.2) kV ENA EG1-2006 Substation Earthing Guide IEEE 80-2000 Guide for Safety in AC Substation Grounding Queensland Electrical Safety Act 2002 Code of Practice: Works Queensland Electrical Safety Regulation 2002 Queensland Work, Health and Safety Act 2011 Queensland Work, Health and Safety Regulation 2011
Page 3 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
The Qld Electrical Safety Act 2002 provides that an electricity entity has an obligation to ensure that its works: (a) are electrically safe, and (b) are operated in a way that is electrically safe
5.3
Safety in Design
Page 4 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
6.2
6.3
Drawings
6.4
Bill of Materials
6.5
Material Ordering
6.6
Work Specifications
Page 5 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Page 6 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Page 7 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
9.2
9.3
Greenlining
Refer to Section 13 of this Manual for details of Construction Testing to be carried out. During the process of continuity testing and associated visual checking of secondary wiring, a working copy of each relevant schematic must be greenlined in accordance with Ergon Energy Quality Document MN000301R167: Greenlining and Bluelining of Ergon Energy Substation Drawings. (Bluelining is for functional testing to be carried out by the relevant Test Work Group). 9.4 As Built Drawings
All construction and test changes to the issued drawings must be marked up, firstly on the workgroups working copy of the drawings, then transferred to the Master copy on site prior to departure from site (or earlier if a significant time period has elapsed since the changes were made and other workgroups on site are dependent on the up to date Master copy also). The Master copy drawings provide the source of the latest information for each workgroup on commencement on-site, as well as the collation of all changes to be forwarded back to the Design Office on completion of commissioning. Refer to the xxxxxxx Substation Controlled Drawings.
Page 8 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Page 9 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
11.11 Construction Barriers and Builders Area The work areas shall be demarcated by the appropriate barrier (i.e. fences, bunting, flags) as defined in P53K05R03: Queensland Electricity Supply Industry Substation Barrier Chart and the project documents. Typically Civil Works requires steel mesh panels and green flags to help contain the area and clearly identify area of work. Refer to Temporary Fence Drawing XXXXX for construction and earthing details. SWP SB0301: Civil Works has additional earthing requirements. Site access must still be available to Ergon Energy Crew at all times to respond to power outages or emergencies. Builders Area/Storage Areas is an area typically nominated on the plan and all storage should be outside the substation away from the site accesses and where no harm can come to the public. Also refer to Security Fencing Section 11.25. 11.12 Geotechnical Report and Survey Construction shall be in accordance with the geotechnical recommendations and the testing requirements for the works. Set out of all works shall be in accordance with the set out drawings and the survey. The existing survey shall be updated as part of the as constructed drawings to represent the finished ground and surface level of the new works. Refer to As Constructed drawings section of this document. 11.13 Design Construction work must only be carried out on For Construction Drawings signed off by a Registered RPEQ. A Drawing Register/Transmittal must accompany the drawings to ensure the correct revisions are being used. The Contractor must review the Design Safety Report to identify any risk or hazards that could not be designed out or where specific control measures are required PW000702F100: Simple Project Risk Management Plan. 11.14 As Constructed Drawings Refer to the Standard and the Site Specific Drawing for As Constructed Drawing requirements. The drawings shall be dated and signed off by the Construction Supervisor stating that the mark ups are an accurate representation of what has been built. These mark ups must be supplied to the Superintendent. Refer to SS XXXX: Civil Works. The finished ground level of the earthworks shall be surveyed for by a registered surveyor for compliance and recorded on the As Constructed Drawings. 11.15 Earthworks The For Construction Drawings shall show the extent of earthworks for the project. The Ergon Energy SS XXXX details requirements for site clearing, spoil, fill, capping layers, compaction erosion and sediment control and testing frequencies. Inspection points are outlined in the Drawing Documents or the Specification and shall be discussed in the Pre-Start Meeting. A Dig Permit is required for all excavations >300mm. For work outside the substation a Dial before You Dig is required along with a dig permit for excavations in the vicinity of the substation. Refer to the following Ergon Energy References: SWMS015 Excavations SWMS015F01 Permit to Dig - Form SWMS015R01 Excavations Job Safety Analysis
Check this is the latest version before use. Page 14 of 33 Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
11.21 Roadworks
11.22 Structural Steel Refer to Standard for Civil Works handling, fabrication requirements and tolerances, erection, surface treatment, welding and earthing requirements. 11.23 Concrete Poles, Towers, Landing Spans and Overhead Lines See SWMS Temporary Support of Poles or Structures 11.24 Concrete Masonry
11.26 Switchyard Surfacing Refer to the Ergon Energy SS XXXX Civil Works for the switchyard surfacing requirements including size, grading and spreading. The finished ground level must be surveyed prior to installing yard stone refer to as constructed drawings section.
Page 15 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Page 22 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Page 25 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
14.4 Metering All metering shall be installed in accordance with Substation Standard SS-2-4.1, the Queensland Electricity Connection and Metering Manual (QECMM) and the relevant Design Drawings. Revenue metering circuits must be sealable at the locations as indicated in SS-2-4.1 and the EESS-100316 Series of Drawings. Metering VT and CT loads must be balanced on all three phases as far as possible. For any 3 phase installation, the least loaded metering winding must not carry less than 80% of the load experienced by the most heavily loaded metering winding. Transducers and meters must be connected to the preferred phases as indicated in the Manufacturers' Installation Guides. In the event of contradiction with the Project Design Drawings, the Designers shall be consulted for clarification.
Page 26 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
14.5.2 Control This Section describes the general requirements for multicore cables, secondary wiring and terminals for all AC and DC circuits, CT and VT secondary circuits, control, alarm and protection circuits. All secondary wiring must comply with the following common requirements, in addition to the specific requirements of other relevant Sections of this Manual: 0.6/1kV PVC/PVC insulated conductor conforming to AS 5000.1 14.5.2.1 Stranded Conductors All Control and Protection Panel wiring must be grey. 14.5.2.2 Installation Secondary cables and wiring must be installed in accordance with document MN000301R166: Construction and Wiring Guidelines for Ergon Energy Substation Panels. In order to minimise induced voltages, cable runs shall, wherever possible, be at right angles to the busbars. Where parallel runs are unavoidable, the multicore cables shall be separated from the busbars by as large a distance as practicable. Within the Control Building, so far as is possible, cables which extend outside the Control Building shall be physically separated from internal cabling and particularly from those cables containing low level signals. Where cables enter the building adequate vermin proofing must be installed. AC and DC circuits must be run in separate cables. Where X and Y protections are used, the X and Y secondary circuits must also be run in separate cables. Cables exiting the Control Building shall be laid neatly in concrete trenches, then, exit the trenches at appropriate points in electrical grade PVC conduits to reach the switchyard equipment, as indicated on the appropriate Cable Route Diagrams and other Associated Drawings. Control cables must not be direct buried and must not be run in the same ducts or conduits as HV cables. Cable segregation distances must be maintained in accordance with SS-1-4.4. Due care must be taken to avoid damage to cables during laying. Winches should not be used and cables must be supported on rollers when running across other cables. Cables must be laid parallel with one another as far as possible, not bunched or crossed, so that each cable may be identified throughout its entire length. Where cables exit from conduits, or enter equipment cubicles for termination, they must be adequately protected against mechanical damage and adequately supported by clamps attached either to the panel or the structure. Upon installation of cables, both ends must be suitably sealed to prevent ingress of moisture, dirt, or vermin (until glanded and terminated). Any exposed outdoor wiring between terminal boxes and cubicles must be wired with PVC/PVC multicore cables protected from ultraviolet light by painting with single pack epoxy paint.
Check this is the latest version before use. Page 27 of 33 Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Page 28 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Page 31 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802
Page 33 of 33
Manual Ver 1
Ergon Energy Corporation Limited ABN 50 087 646 062 Ergon Energy Queensland Pty Ltd ABN 11 121 177 802