Design Knowhow: Low voltage substation layouts,

earthing, fire protection and tests

electrical-engineering-portal.com/design-knowhow-low-voltage-substation-layouts-earthing-fire-protection-tests

By Mohammed Ayman April 3, 2023

11kV/415V Substation Design

The design of a low-voltage substation is a pretty complex and quite exciting job to do. If
the designer would have complete freedom to make decisions regarding the substation
layout, equipment, or cable routes, the job will be even more challenging! Well, this article
will try to shed some light on the main design aspects of the 11kV/415V substation layout,
structure, earthing and fire suppression systems.

Design Knowhow: Low voltage substation layouts, earthing, fire protection and tests

Since this type of substation is implemented to feed and distribute power to an entire
project, learning about the major design considerations and the required clearances
inside the room becomes necessary.

The design of a substation inside a building may have different design layouts that need
to be studied to know more about how electrical equipment, such as transformers, LV
panels, RMUs etc., are installed inside the room.

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Different layouts are elaborated on in this article. The equipment inside the substations
MUST be protected from potential fire incidents, which means that a substation must
contain different types of firefighting and fire alarm systems that are interfaced
together to provide full protection in case of fire.

This article will reveal the interfacing between these systems inside the substation.
Although understanding the interior of a substation and how it should be protected from
fire incidents is vital, learning more about the required testing procedures that will be
performed for the panels before energizing a new substation is just as important.
This article explains the major tests that need to be carried out step by step to deliver a
safe, reliable and protected substation.

Table of Contents:

1. Structure of an LV Substation
An LV substation or an LV room typically contains standing switchboards and other
equipment required for the room to function, such as bus ducts and cable containments,
panel boards, capacitor banks, air conditioning system, fire alarm system, firefighting
system, lighting, small power etc. The latter systems are required to build a typical indoor
LV substation.

However, before indulging into more details about the LV substation’s structure, it is
crucial to have a brief on how the medium voltage substations, including the MV
switchgear and the transformer, supply an LV substation.

To comprehensively understand how electric power is delivered to LV substations, you will

need to track the source of electricity going through the stages of its delivery. Electricity
passes through three stages: generation, transmission and distribution.
Electricity is first generated in power plants or stations with a voltage of 11kV, then
stepped up using step-up transformers to increase the voltage to between 100 kV to
700kV depending on the distance it will be transferred to; the longer the distance, the
higher the voltage.

After that, electricity is transmitted via overhead electrical lines, which you can see when
you drive between cities (see bottom for ‘Commercial load’).

Figure 1 – A 24-bus system, showing generation, transmission, subtransmission,

industrial, and commercial loads

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 Figure 1 – A 24-bus system, showing generation, transmission, subtransmission, industrial, and
commercial loads

The transmission of these lines is aimed at reaching several receiving HV substations.

When electrical power reaches a receiving station, the voltage decreases to 33kV and
66kV. It is then sent to transmission lines from this receiving station to electrical
substations close to cities, villages, and urban areas. When electrical power reaches a
substation, it is stepped down once more by a step-down transformer to voltages closer
to what it was generated at, usually around 11kV.

From here, the transmission phase graduates to the distribution phase, and electrical
power is used to meet demand from primary and secondary consumers. This is done by
installing an MV voltage switchgear/ RMU (Ring Main Unit) that can supply several low-
voltage transformers that decrease this voltage to 500V or less for distribution and
utilization purposes.

This article will focus on the LV substation connected to the LV transformer substation. LV
substation is implemented to distribute low voltage power to the consumer with a voltage
between 100V to 500V for single and three-phase loads.

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By looking at the figure below, we can understand more what makes up an LV substation.

Figure 2 – Low voltage substation

Figure 2 – Low voltage substation

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2. How to Start With the Design?

Designing the LV part of an LV substation can only be done by taking some
considerations in mind. The 11kV/0.45kV substation can either be located indoors or
outdoors. The most likely type of LV substation used for supplying customers with less
than 500V is located inside the building and distributes power to the entire project, and
should be designed to meet the safety requirements to avoid any dangerous situations.

The LV substation MUST be designed to provide a reliable service, facilitate maintenance

and allow for future expansions.

In other words, at least 20% spare capacity should be provided for every equipment
inside the room, including cable trays, trunks, LV switchboards, etc. Below are some
major requirements that must be complied with inside an LV substation.

1. Access for personnel (normal and emergency).

2. Access for equipment (installation, operation and maintenance).
3. Regulatory compliance and approvals.

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 4. Cable containment and entries.
5. Earthing and grounding.
6. Water sealing (if below ground).
7. Air conditioning, lighting & small power.
8. Fire detection, alarm and suppression.

Figure 3 – Inside an LV/MV Substation

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 Figure 3 – MV/LV substation installation layout (all dimensions are in millimeters)

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2.1. Equipment Clearances You MUST NOT Be Wrong About

The internal clearances of an low voltage room must always follow international
standards like NEMA, BS and NFPA. Equipment such as trays, LV switchgear, capacitor
banks etc., are usually located and placed following these standards. In many countries,
LV substation design drawings are be approved by the main electrical authority before
building construction.

This is why dimension considerations must be made during the design stage.

Electrical authorities might only supply the building with power if the requirements are
met. In a typical LV substation, cable trays are installed to facilitate the outgoing and
incomer cables. These trays should be designed to be located with sufficient clearances
around them to permit adequate access for the installation and maintenance of cables.

The following are the major requirements for the tray design in a substation:

1. 300 mm minimum clearance from the ceiling to the cable tray is required.
2. A minimum distance of 50mm between the tray and the vertical wall.
3. 300 mm minimum clearance is required from the side of the cable tray to provide
easy access to the cables installed on the tray for inspection or future modifications.
4. 300 mm minimum vertical clearance is required between two parallel trays.

Inside an LV substation, other equipment clearances must also be considered. For

example, switchgear inside the room MUST have adequate space side to side, front,
back and height. The clearances around switchboards MUST comply with local
regulations; however, in the absence of local guidelines, the following minimum can be
used for switchboards:

Minimum 1.5 m front clearance.

Minimum 0.75 m rear clearance.
Minimum 1.00 m side-to-wall clearance.
Minimum 0.75 m side to another cubicle/PFC panel clearance.
Minimum of 0.75 m clearance for ventilation around capacitor bank(s).

By looking at the below figure, we can have an idea about the required clearances from
all  sides of the switchgear inside the substation.

Figure 4 – LV Switchboard required clearances

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 Figure 4 – LV Switchboard required clearances

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2.2. Dozen of Layouts Available (How to Choose)

Depending on the location of the LV substation, it can differ in the layout design. An LV
substation is usually adjacent to the transformer (Tx) room. It could share the same wall
as a transformer room and be connected by a trench, facilitating the cables between the
rooms by sleeves in the wall.

In this type of room, cables are connected between the LV side of the transformer(s) to
the LV switchboard/s inside the LV room. The trench depth and dimensions should
comply with the local regulations in the first place.

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The below layout shows the two rooms (Transformer and LV) adjacent to each other,
which minimizes the distance of cables between each.

Figure 5 – Low voltage substation room (type one)

Figure 5 – Low voltage substation room (type one)

The above diagram shows a trench inside the LV switchgear room connected to the
transformer room using sleeves inside the wall to lay cables between the rooms. The
figure below shows the trench section with the sleeves in the wall.

Figure 6 – Cable trench detail

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 Figure 6 – Cable trench detail

The photo below shows cables laid on the floor before they are laid inside the trench and
connected to the bottom side of the low voltage switchgear.

Figure 7 – Low voltage cables before being laid in trench of an LV room

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 Figure 7 – Low voltage cables before being laid in trench of an LV room

LV room layout can also be designed differently. Trenches are not always necessary, and
it all depends on the cable entry side of the LV switchboards. In other words, the
switchboards can either be bottom or top-entry types. Top entry panels not always not
require floor trenches; instead, cable trays are terminated on top of the panels.

For example, the lower figure is of an LV room connected to the transformer room using
cable trays without a designed trench. The connection between the transformer and the
panels here uses busbars, which is also an alternative cable connection.

The rectangular opening on top of the panels here indicates that the transformer room is
on the upper floor and connected to the switchgear incomers by either busbars or
cables.
In contrast, the outgoings that supply the sub panels will be through cables, which can be
carried by cable trays.

Figure 8 – Low voltage room type two

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 Figure 8 – Low voltage room type two

Below is the actual site photo of the above LV room layout. It shows an LV substation with
top entry cables and busbars.

Figure 9 – Top-entry low voltage panel

Figure 9 – Top-entry low voltage panel

The previous LV rooms were explained based on the cable’s connection; however, MV/LV
or 11/0.45KV substations can be designed with other details layouts like:

1. Substation with RMU and feeder switch.

2. Substation with RMU only.
3. Substation with RMU and feeder switch without LV room.

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 4. Substation with RMU only and without LV room.

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2.2.1 BONUS! The Most Common LV substation Layouts (PDF)

You may have a look at the difference between each of these layout details by
downloading the following PDF file.

Download LV Switchgear layouts in PDF format:

Download (PDF)

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3. Fire protection Interfacing inside an LV substation

Many systems can be designed for an LV room to increase its safety and protect the
switchboards inside in case of fire. For instance, the fire alarm and FM 200 firefighting
system are critical to implementing inside the LV substation. By having a clean agent
system(FM 200) inside the room, during a fire, the released gas will act immediately to
extinguish the fire without causing aftereffects.

Unlike water sprinkler systems, FM 200 is used in substations without causing damage to
the electrical and electronic equipment. Along with the firefighting system, the fire alarm is
interfaced to ensure the smoke detector detects the fire at the early stages before the
FM200 system is triggered to release the firefighting gas.

The figure below shows a 3D view design of the FM200 system designed for a
substation. Moreover, upon detection of fire, the fire alarm control panel send a signal to
the HVAC control panel to shut down the air conditioning unit supplying the LV substation
to control the spread of smoke inside the room.

This will also apply to all kinds of substations, not only LV.

Figure 10 – FM200 fire-suppression system inside an LV room (3D layout)

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 Figure 10 – FM200 fire-suppression system inside an LV room (3D layout)

Because of its advantages, the FM 200 is the most often used suppression system for
power substations. System consists of a gaseous agent stored in a cylinder, a valve to
release the agent of demand, a fire detector that detects fire at an early stage, a control
panel that receives the detection single from the detector and sends a signal to the valve
and alarm, piping to carry the gaseous agent to be released, and nozzles to disperse the
gaseous agent in the power substation.

In the event of a fire, the detectors detect it early and send a signal to the control panel.
The control panel then sounds the pre-discharge alarm and instructs the electric solenoid
actuator to release the gaseous agent through the nozzles. At the same time, the control
panel activates the discharge alarm and turns on the discharge strobe light.

In addition, a manual discharge switch is provided to commence discharge if necessary.

To increase the reliability of a fire suppression system, it can be provided with a backup
gas agent cylinder in addition to the main cylinder.
The control panel should be powered by a UPS and should have built-in batteries.

Figure 11 – Fire suppression schematic

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 Figure 11 – Fire suppression schematic

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4. Earthing System Inside an LV Substation

There is always a chance of potential faults with the loads connected from the dedicated
LV panel inside the LV substation; therefore, connecting the LV panel to a separate
earthing source is crucial. In other words, all LV panels inside an LV room MUST be
earthed by connecting a separate earth cable from the busbar of each panel to an earth
bar in the same room dedicated to the LV system, as shown below layout figure referred
to as Test Link.

The figure below shows a typical 11/0.45KV substation layout which includes four rooms:
RMU or MV, Transformer, LV and a generator room. Every room has its own busbar or
test link that is eventually connected to the LV earth pits outside. These pits are only
dedicated for LV system.

For example, connecting LV panel earth cables to an ELV (Extra Low Voltage) earth pit is
not recommended since these two systems have different voltages and MUST be
earthed separately.
The layout below also shows the LV panel’s earth busbar is connected to the main test
link of the LV room located nearby the door. Which means earth cables for each circuit
breaker connected inside the LV panel is connected to the main earth of the LV room. In
this way, any fault current at any connected loads will guarantee its way to earth.

Figure 12 – MV/LV substation earthing layout

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 Figure 12 – MV/LV substation earthing layout

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5. Requirements Before Testing Panels

5.1. General Notes

After LV panels are installed inside a substation, testing are carried out to ensure a
healthy distribution system will be supplied to the customer. Below are some useful notes
that should be followed on-site before testing.

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 1. The LV panels should be inspected at the site by a dedicated project consultant.
2. LV panel installation should be inspected per the consultant’s approved shop
drawings.
3. The installation of LV panels & Capacitor banks should be carried out according to
the approved drawings from the authorities and as per specifications.
4. The LV panel earthing system MUST be installed.
5. LV panel accessories inside the substation should be from the same manufacturer.
6. All cables and equipment inside the LV room MUST be properly labelled and
ferruled per IFC/shop drawings and project specifications.
7. All tools and test equipment/devices MUST have a valid calibration test.
8. Calibration tag/sticker MUST be seen in the device or equipment, and all data must
be visible and readable.
9. LV panel Factory Acceptance Testing (FAT) valid report MUST be available before
site testing.
10. Dedicated safety personnel MUST ALWAYS be present in any testing &
commissioning activities for the LV panels & Capacitor banks.
11. LV panel manufacturer or supplier representatives are desirable to be present
during the T&C activities.
12. LOTO processes and procedures MUST be obtained before T&C and power supply
energization activities.
13. All LV panel circuit protection, circuit breaker, contactor relay and related device
parameters MUST be set per technical and project specifications (protection
coordination studies).

Suggested Reading – Lock-out tag-out practice and seven other steps that save lives

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5.2. Pre-Commissioning Procedures

Following the pre-commissioning procedures, the substation engineer must:

1. Check that the installation location of panels inside the room is free of water or
construction debris.
2. Repair / Replace damaged components if any.
3. Ensure that the LV and other panels are properly tagged and identified location-wise
and service-wise as specified.
4. Ensure the wiring termination to the LV panel and capacitor bank is complete.
5. Ensure that the outgoing cables from the LV panel are terminated in the respective.
6. Ensure that the earthing of the LV panel is completed.
7. Ensure the availability of power supply to the LV panel.
8. Ensure that the cables to the LV panel are properly tagged and identified.
9. Ensure that the rating of the breakers is as per approved shop drawings &
schedules.

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 10. Ensure the metering connections are proper and the meters are healthy.
11. Check all the breakers in the LV panel manually.
12. Check that the termination of the cables to the bus bar is tightened properly.
13. Ensure that all manufacturer’s instructions are carried out as stated in the test
procedures of the LV panel.

Suggested Course – Learn AC Distribution Panel Drawings: SLDs, Wirings, and

Interlocking Schematics

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6. Tests after erection of LV panels

The following tests and checkups MUST be carried out after LV panels are erected:

1. Power frequency voltage tests on the completed switchgear.

2. Insulation resistance tests on all main and secondary circuits.
3. Calibration checks on ammeters, voltmeters and any other instruments.
4. Testing at normal voltage to prove that closing and tripping from local and remote-
control points, tripping from relays and protective gear, interlocks, alarm and
indications etc., are satisfactory.
5. At the end of the tests, the protective relays and breaker tripping times must be set
following the approved discrimination coordination.

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6.1. Insulation Resistance Test (IR)

This test is conducted to ensure the health of the insulation of the LV switchboard
cables to avoid short circuit or ground fault when the power distribution boards are
energized. It must be conducted when power supply is not live, all the circuits dead or not

energized, and the neutral link disconnected before and reconnected after tests.

Figure 13 – Insulation/ Megger Test Connection

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 Figure 13 – Insulation resistance testing: HV – Earth and HV – LV

Test Procedure
a) Line (Positive) and Neutral (Negative) conductors to Earth
1. Complete the connection set-up as shown in the figure above.
2. Set the test voltage on the instrument to 500 Vdc.
3. Connect the test leads between the line conductor (positive and negative) linked
together and the earth conductor, as shown in the figure above.
4. Operate the instrument test button to apply the test voltage and record the
insulation resistance reading (Mega-ohm) in the test form.
5. All data must be recorded on the approved form.
6. All readings found with discrepancies must be rectified.

b) Between Line Conductors

1. Complete the connection as shown in the figure above.
2. Set the test voltage on the instrument to 500Vdc.
3. Connect the test leads between the R-phase and the other line conductor, as shown
in the figure above.
4. Operate the instrument test button to apply the test voltage and record the
insulation resistance reading (Mega-ohm) in the test form.
5. Repeat the procedure to test each of the other line conductors, with the remaining
always linked together.

Acceptance Norm: The regulation requires the insulation resistance to be not less than
1.0 M ohm according to IE standards.

Important Note: All tests MUST be carried out in the presence of the qualified engineers.

Suggested Guide – Guide To Modern Insulation Testing (Practical Usage)

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6.2. Cable Continuity & Polarity Check

This test MUST ensure the continuity of the LV Switchboard system cables and the
correctness of cable connections. Like insulation test, it has to be conducted with no
power supply connected, all the circuits dead or not energized, and the neutral link
disconnected prior to tests and reconnecting after the test.

Test Procedure

Continuity of line (Positive), Neutral (Negative) and Earth Conductors:

1. Select continuity test mode on the digital multi-meter (indicated with a buzzer
symbol).
2. Connect a shorting link between the R-phase (positive) and the earth conductor on
one end, as shown above.
3. Connect the test lead of the meter between the R-phase (positive) and earth
conductor to the other end, as shown above. A buzzer sound will be heard when
continuity exists between the two linked conductors; otherwise, one is either broken
or wrongly wired. Check the wiring until the correct continuity test result is obtained.
4. Repeat the same procedure to check the continuity of the Y and B phase and the
neutral (negative) conductors, except that the shorting link should be placed
accordingly.
5. During tests, identify to confirm and record correct polarity.
6. Record the final test result in the test form.

Figure 14 – Cable continuity test procedures

Figure 14 – Cable continuity test procedures

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6.3. Phase Rotation Check

The phase rotation of each LV Switchboard is checked to verify the phase rotation
sequence (R-Y-B). This test is performed to ensure the sequence of the three phases to
assure that the motors connected to the system will be rotating in a prescribed direction
when energized.

Test Procedure

1. Check the phase rotation indicator type whether it is clockwise disc rotation type or
anticlockwise disc rotation type.
2. Check the connecting wires of the R-Y-B leads of the meter to the R-Y-B of a known
trusted three-phase source to confirm the direction of operation.
3. Connect the 3 test leads to the three-phase busbar or terminals of the source to be
tested.
4. Check the rotation per the meter type and record the result on the record sheet.

Figure 15 – Phase rotation test applied on site

Figure 15 – Phase rotation test applied on site

Suggested Video – How to: Phase Rotation Testing

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Watch Video At: https://youtu.be/iC_QiGo66Zk

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6.4. Functional Test

Functional test is performed to verify that the panels are ready to be energized within the
LV substation.

1. Check the pre-commissioning form to verify that pre-commissioning checks and

tests have been completed and that the equipment is confirmed safe and ready to
be energized.
2. Repeat visual and mechanical checks paying particular attention to correct cable
termination, polarity, adequate access to devices, proper grounding connections
and the secure attachment of cable terminals and connections.
3. Upon confirmation of the equipment’s readiness for operation, operate the incoming
power supply of the LV panels from its upstream feeder power source to ON
position.
4. Check to confirm the phase rotation of the incoming power supply using a phase
rotation meter.
5. If the phase sequence (R-Y-B) is correct, the phase rotation meter will indicate the
direction established in the phase rotation check carried out above.
6. Check the availability of incoming power supply at the supply side terminals of the
LV panel’s main breaker using a multi-meter and confirm the phase-to-phase and
phase-to-neutral voltage supply.
7. Check to confirm the phase rotation of the incoming power supply using a phase
rotation meter. If the phase sequence (R-Y-B) is correct, the meter will indicate the
direction established in the phase rotation check carried out.

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 8. Check to confirm the availability and value of the phase-to-phase and phase-to-
neutral voltage at the main bus bar.

The LV panel is now deemed operational, and all the outgoing circuit breakers are now
ready to be operated to “ON” and energized to feed their respective loads. So, after
performing the above-mentioned tests and obtain the healthy results for all panels, we
can say that:

The LV substation is functional and ready for operation and energization to

supply the downstream loads.

Further Study – The most important precautions during commissioning and start up of LV
switchgear

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