GCS 5000

Version 1.0: Sept. 15, 2008

Guidelines for
Substation Constructions

General Electricity
Company Of Libya
 Table of Contents

1. Scope 1
2. General 1
2.1. Substation Types (Refer to GDS 5000, clause 2.2) 1
2.1.1. Outdoor AIS 1
2.1.2. Outdoor GIS 1
2.1.3. Outdoor hybrid GIS 1
2.1.4. Outdoor full GIS 1
2.1.5. Indoor GIS 2
2.1.6. Indoor AIS 2
2.1.7. Underground GIS 2
2.2. Review of Required Area 2
2.2.1. Overview 2
2.2.2. Equipment Arrangement 3
2.3. Flowchart for Substation Construction 4
3. Construction Process Management 5
3.1. Making a Master Time Schedule 5
3.1.1. Objectives 5
3.1.2. Process for master time schedule 5
3.1.3. Master time schedule details 6
3.1.4. Approval and submission time for MTS 7
3.2. Construction Management 8
3.2.1. Starting construction 8
3.2.2. Construction management 8
3.2.3. Master time schedule verification 9
3.2.4. Construction verification 9
3.2.5. Measuring work 9
3.2.6. Review on special construction methods 10
3.2.7. Review of applied techniques 10
4. Construction Supervision 11
5. Safety Management 11
5.1. Safety Management Organization 11
5.1.1. Duty 11

ii
 5.2. Safety Inspection 12
5.2.1. Kinds of safety inspection 12
5.2.2. Methods of safety inspection 12
5.2.3. Inspection item 13
6. Material control 13
6.1. General 13
6.2. Installation Conditional Material 13
7. Quality management 13
7.1. General 13
7.2. Priority Quality Management 14
8. Environmental Countermeasures 14
8.1. Noise and Vibrations 14
8.2. Water Contamination 14
8.3. Land 15
9. Post-Construction 15

Appendix 1. Safety Inspection(General) 16

Appendix 2. List of Safety Equipment 17

Appendix 3. List of Tools and Equipment 18

iii
 List of Tables

<Table 1> Calculation results 3

<Table 2> Overall concept 6
<Table 3> Basic duties for Clients, Supervisors and Contractors 11
<Table 4> Safety Inspection (General) 16
<Table 5> List of Safety Equipment 17
<Table 6> List of tools and equipment 18

iv
 List of Figures

[Figure 1] General flowchart for substation construction 4

[Figure 2] Master time schedule 5
[Figure 3] Construction management 8
[Figure 4] Measuring Work 10

v
 Guidelines for Substation Construction

1. Scope
This standard covers construction work for the Libyan power system 66/11kV and
30/11kV substations.

2. General
Based on economic development and rapid increases in power demand, additional
substations are required in Libya. In a power system, substations play an important role. If
a breakdown occurs at the substation, it has a serious effect on the rest of the system.
Therefore power quality should be improved by developing advanced equipment and
managing a stable power system. Improving power quality should start with substation
construction, in accordance with process management and quality management.

2.1. Substation Types (Refer to GDS 5000, clause 2.2)

2.1.1. Outdoor AIS
The buses and associated equipment (such as transformers, circuit breakers, disconnecting
switches) are exposed to air. They are connected together by means of an aluminum tube or
ACSR (Aluminum conduct steel reinforced) with insulators installed in supporting
structures. The buses may be multi-tiered or spread out.

2.1.2. Outdoor GIS

The buses and associated equipment such as circuit breakers, disconnecting switches in
the GIS type substation are housed in pipe-type enclosures insulated by SF6 gas. GIS can
be classified into two types.

2.1.3. Outdoor hybrid GIS

The hybrid GIS is where power transformers, circuit breakers and transmission lines are
connected together by means of an AL (aluminum) Tube or an ACSR. Some of the live
parts are exposed to air.

2.1.4. Outdoor full GIS

The full GIS has no live exposed parts, except at the outlet section. Full GIS substations
can be very compact. However, construction costs are very high and equipment installation
is difficult.

GECOL Sept. 15, 2008

1 /18 Version 1.0
 Guidelines for Substation Construction

2.1.5. Indoor GIS

All equipment (transformers, circuit breakers, disconnecting switches, etc) is installed in
an exclusive building. Most of the features are equivalent to outdoor GIS. The biggest
difference is that all equipment is protected completely from contamination by salt spray,
dust and moisture. The substation size is the most compact.

2.1.6. Indoor AIS

The buses and associated equipment (transformers, circuit breakers, disconnecting
switches, etc) are connected together by means of an aluminum tube or ACSR (Aluminum
conduct steel reinforced) with insulators installed in supporting structures. This type is
similar to the outdoor AIS. However it needs an exclusive building to accommodate all
facilities.

2.1.7. Underground GIS

All of the features of underground GIS are the same as the indoor GIS. The biggest
difference is that all equipment is installed underground. Nowadays, this type is adopted in
urban areas, shopping streets, schools and hospital areas where it is difficult to secure
construction land.

2.2. Review of Required Area

2.2.1. Overview
The area required for substations is an important consideration. Construction costs are
influenced by land security, land costs and civil engineering costs. The required area
becomes an issue where a substation is constructed in a downtown area. The land cost is
expensive and land security is difficult due to public complaints. In mountainous areas,
large civil engineering costs are required for site development.

Considering construction sites in Libya, it is expected that the land security is not difficult
and civil engineering costs have no great effect on the overall construction cost. However,
a smaller area is better for efficient utilization of national land. Based on this, the required
area of each substation type was compared.

Considering future extensions, required area shall be decided according to the final scale
suggested in the long-term system plan. The required area of each type was calculated
assuming the equipment arrangement as shown in GDS 5100.

GECOL Sept. 15, 2008

2 /18 Version 1.0
 Guidelines for Substation Construction

2.2.2. Equipment Arrangement

(a) Substation scale
A. 30 kV Substation
i. Power transformer: 30 kV, 25 MVA, 2 Banks
ii. Feeder: 30 kV 6 feeders, 11 kV, 14 feeders
B. 66 kV Substation
i. Power transformer: 66 kV, 25 MVA, 2 Banks
ii. Feeder: 30 kV 6 feeders, 11 kV, 14 feeders

(b) Bus-bar scheme

A. 30 kV Substation
i. Double bus and single breaker
B. 66 kV Substation
i. Single bus and single breaker
ii. Double bus and single breaker

<Table > Calculation results

Substation Type Installation area (m2) Remark
30 kV Indoor GIS 1290.42 m2 (40.2 × 32.1) Double bus
4184.28 m2 (78.8 × 53.1) Double bus
Outdoor AIS
3774.52 m2 (78.8 × 47.9) Single bus
2170.00 m2 (50.0 × 43.4) Double bus
66 kV Outdoor GIS
2170.00 m2 (50.0 × 43.4) Single bus
1907.60 m2 (50.2 × 38.5) Double bus
Indoor GIS
1907.60 m2 (50.2 × 38.5) Single bus
Indoor AIS 2189.2 m2 (52.0 × 42.1) Single bus
Note:
1. Installation areas include the access road required for substation construction
2. Detailed areas refer to the substation layout described in GDS 5100, however, this layout
is only for reference to estimate the required area

As shown above, the outdoor AIS requires more than twice the area of the indoor GIS
(based on the 66 kV substations).

GECOL Sept. 15, 2008

3 /18 Version 1.0
 Guidelines for Substation Construction

2.3. Flowchart for Substation Construction

Long term power system plan

Site Selection
Site Acquisition Stage

Permission

Site Purchase

Basic Design and Key Points

Procurement
Design and Contract Stage

Detail Design

Contract

Construction

Commissioning
Construction and Completion Stage

Energizing

Completion

GECOL Sept. 15, 2008

4 /18 Version 1.0
 Guidelines for Substation Construction

[Figure ] General flowchart for substation construction

3. Construction Process Management

3.1. Making a Master Time Schedule
3.1.1. Objectives
When the contractor starts substation construction, the contractor shall make a master
time schedule. The schedule will set basic construction courses and to systematically
manage construction, processes, safety, quality, sub-construction and environment
management. Consequently, the master time schedule makes the construction methods and
quality more efficient.

3.1.2. Process for master time schedule

Contractor Supervisor GECOL

Making a MTS ⊙ Review on MTS

⊙ Check each standard
and regulation

Review &
Approval
No

Yes <Reference>
GDS
GES
GCS
Construction

MTS : Master Time Schedule

[Figure ] Master time schedule

GECOL Sept. 15, 2008

5 /18 Version 1.0
 Guidelines for Substation Construction

3.1.3. Master time schedule details

<Table > Overall concept

Item Main contents
1. Objectives
2. Outline  Scale, period, procurement for construction
3. Process
 Monthly time schedule. Includes preparation,
3.1 Time schedule earthing and foundations, equipment installation,
Panel installation and control cable laying.
3.2 Process
 Plan interfaced with other processes
management
3.3 Counter plan to  Analyze poor progress
prevent poor progress  Create a counter plan to prevent poor progress
 Standard time schedule
3.4 Progress
 Submission time
management
 Manpower and equipment plan
4. Construction site
management
4.1 Construction site
 Construction site address and telephone numbers
office
4.2 Safety management  Organization from work leader to site representative
organization  Describe positions and names

4.3 Construction  Division of work, number of workers

organization  Organization diagrams

5. Safety management
 General safety regulation
plan
5.1 Safety management
 Diagrams, roles
organization
5.2 Safety meeting  Objectives, period, personnel, meeting details

GECOL Sept. 15, 2008

6 /18 Version 1.0
 Guidelines for Substation Construction

plan
5.3 Construction safety
 Safety plan for each phase
plan
5.4 Safety check plan  Types, methods and details for safety check
5.5 Safety facilities  Facility name and standards, considering
installation plan construction progress
5.6 Individual safeguards
 Proper safeguards for each progress
supply plan
5.7 Manpower and
 Manpower and equipment for each phase
equipment plan
5.8 Protection plan  Risk management protection plan
5.9Emergency manpower
 Additional manpower planning
System
6. Quality assurance
plan
6.1 Quality assurance  Quality management policy, the purpose, and
plan and procedure organization system
6.2 Quality control plan  Plan and procedure

3.1.4. Approval and submission time for MTS

(a) Approval : the contractor shall start construction after receiving the supervisor’s
approval for every construction unit
(b) Submission time : 20 days before starting each construction unit

GECOL Sept. 15, 2008

7 /18 Version 1.0
 Guidelines for Substation Construction

3.2. Construction Management

Constructing a substation should be done via quality acquisition, construction
management and efficient process management during the construction period.

Figure 3 shows substation construction management processes.

Start Construction
Construction Management

Review of Construction MTS review

Applied management
techniques

Review of Construction
Special methods Verification

Measuring
Work

[Figure ] Construction management

3.2.1. Starting construction

Appoint and arrange the supervisor after accepting the construction execution request.

3.2.2. Construction management

(a) The supervisor shall verify whether construction work is performed suitably,
according to contract documents, construction specifications and related regulations.

GECOL Sept. 15, 2008

8 /18 Version 1.0
 Guidelines for Substation Construction

(b) The supervisor shall manage that substation construction is completed with good
quality during the construction period.
A. Each result measured by contractor
B. Review detailed schedules for each phase
C. Verification for each stage
3.2.3. Master time schedule verification
(a) The supervisor has to review construction plans submitted by the contractor.
(b) The supervisor has to review the MTS whenever it’s changed.
(c) Construction detail designs should be drawn clearly in order to ensure construction
safety. The supervisor and contractor shall review selected construction detail designs
according to construction conditions.
(d) Don’t permit construction before detailed reviews of drawings.

3.2.4. Construction verification

(a) The supervisor must check all work stages including manufacturer, assembly, and
installation.
(b) The important checking points are to confirm construction design drawings,
specifications and related regulations. If necessary, the supervisor is able to add
specifications to be checked.
(c) The supervisor can require construction records such as detailed progress documents
and pictures taken by other personnel, when it is difficult to check construction works
such as underground and water based facilities
(d) The supervisor regularly checks construction progress to promote efficient
construction
(e) The supervisor has to take action when unsuitable practices are found. These may
include illegal activities, sub-standard construction or other unacceptable
abnormalities.

3.2.5. Measuring work

(a) When performing the field measuring work, an inspector should record results by
using a check-list, and notify the contractor of the results.
(b) An inspector shall quickly decide criterion regarding construction standards or pass
standards for measuring content.
(c) Difficult measurements, such as concrete work, should be conducted under
supervision.

GECOL Sept. 15, 2008

9 /18 Version 1.0
 Guidelines for Substation Construction

Field
Construction Contractor’s
technical Submit
examination Supervisor’s
field Announce
examination
completion check request examination result

NO
Re-construction Acceptance

YES

Next stage
Inception

[Figure ] Measuring Work

3.2.6. Review on special construction methods

When special methods are used during the construction stage, the supervisor shall decide
whether to utilize special construction methods, after seeing professional advice.

3.2.7. Review of applied techniques

(a) When construction field problems occur, to prevent delays, the supervisor shall solve
any problem via field inspections, reviews and analysis.
(b) A written review of important techniques shall be submitted providing technical
detail.

GECOL Sept. 15, 2008

10 /18 Version 1.0
 Guidelines for Substation Construction

4. Construction Supervision
An objective of supervision is to obtain and supply high quality, stable power through
acquisitions, construction management, safety management and efficient process
management.

<Table > Basic duties for Clients, Supervisors and Contractors

Classification Basic duties
 General overall plan, design, ordering, supervision, construction,
Client assessment of power facilities and so on.
 Guide and check whether work complies with regulations
 Check that the construction is accomplished in accordance with
design drawings, related documents, and regulations.
 Technical guide for managing quality, process, safety, environment
Supervisor
and so on
 The supervisor isn’t a subordinate to client, the supervisor shall
perform all duties independently, according to the contract
 According contract documents, the contractor shall undertake
construction to the best of their ability. The contractor is also in
charge of field work and guaranteeing construction methods.
Contractor
 The contractor shall complete the construction period on time. When
the supervisor requests re-construction, stop work or other
comments, the contractor shall follow the supervisor’s directions.

5. Safety Management
The purpose of this standard is to present safety rules and methods. Such standards assist
and protect personnel and the general public during substation construction. Safe
construction methods shall be practiced and maintained at all times and on all phases of
work.

GECOL Sept. 15, 2008

11 /18 Version 1.0
 Guidelines for Substation Construction

5.1. Safety Management Organization

5.1.1. Duty
5.1.1.1. Safety manager
In order to prevent accidents, the safety manager shall make a safety plan as in
cooperation with the site agent.

5.1.1.2. Site agent

(a) Understand overall process details and site circumstances before starting works.
(b) Give site workers training about work procedures, individual works, dangerous
factors, and treatment and prevention of accidents.

5.1.1.3. Safety clerk (in charge of site safety)

(a) Understand dangerous site factors and assist the site agent.
(b) Check safety devices and whether site workers use appropriate safety equipment.
(c) Check personnel health conditions.

5.2. Safety Inspection

5.2.1. Kinds of safety inspection
5.2.1.1. Self inspection
(a) Daily inspections: check that each site worker complies with safety regulations and
uses appropriate safety equipment.
(b) Weekly inspections: This inspection is coordinated by the safety manager and safety
clerk, who will check the following:
A. Inspect environmental facilities within work areas
B. Initiate discussion and construction methods for new technique
C. Inspect the safety check-list
(c) Random inspections: overall inspection and modifying plans regarding self-
inspection matters by inviting special inspectors to the site

5.2.1.2. Special inspection

In order to prevent accidents, all areas must be inspected before the rainy season. For
example, the inspector should prepare the check-list and inspection scope one month
before the rainy season. Then the inspections must take place over two weeks. Finally, one
week before the rainy season, preventative countermeasures should be carried out.

GECOL Sept. 15, 2008

12 /18 Version 1.0
 Guidelines for Substation Construction

5.2.2. Methods of safety inspection

(a) Visual inspection
(b) Functional inspection
(c) Inspection by machine or equipment

5.2.3. Inspection item

Inspections are performed via an inspection check-list, which considers the following:
(a) Categorize and confirm - good, unsatisfactory, poor
(b) Concrete inspection details
(c) Consider normal fault frequencies and danger rates for inspection equipment
(d) Set the inspection level limit considering inspector’s abilities

6. Material control
6.1. General
(a) For material storage, it is necessary to secure a warehouse and rent a security guard
resident.
(b) A warehouse shall be the proper site to store, load/unload, and avoid corrosion,
deterioration, flooding and so on.
(c) Materials should be always arranged categorically. The security guard or warehouse
clerk shall take great care to prevent theft and damage.
(d) When moving or managing materials, be careful no to damage or lose materials.

6.2. Installation Conditional Material

(a) Materials which need special care and technique are called installation conditional
material. Their manufacturer is responsible for transportation, installation and
commissioning. Representative materials are the power transformer and gas insulated
switchgear.
(b) Design, contract and installation are separated from main construction contract.

7. Quality management
7.1. General
(a) The supervisor shall check whether the contract document, work plan, instructions,
etc. meet with relevant regulations and strictly conform to quality control for each
step of construction.

GECOL Sept. 15, 2008

13 /18 Version 1.0
 Guidelines for Substation Construction

(b) When inspecting the construction site, the supervisor shall prepare a construction
quality check sheet and add details according to site conditions.
(c) The supervisor shall receive the inspection and test plan from the contractor. The
supervisor will inspect construction procedures according to approved ITP. If the
inspection results violate standards, the supervisor shall manage non-conformance
quality control procedures and take appropriate action.
(d) The supervisor shall meet quality control conditions for regulations, schedules,
procedures and specifications as issued by client.

7.2. Priority Quality Management

(a) The supervisor selects priority construction, considering the priority of all stages, by
reviewing design drawings, specifications, progress plans, etc. The supervisor will
then preferentially manage priority constructions above other stages.
(b) When selecting priority constructions, consider the following:
A. Test item and times according to progress plans
B. Number of personnel required to manage quality
C. Work conditions for each construction stage
(c) Management method
A. The supervisor shall announce quality management methods for priority
construction to the client and contractor.
B. The priority progress should be marked on a status plate, recognized by
workers, engineers and contractor
C. When making a progress plan, the supervisor shall adjust several priority
projects, to avoid having them all start at the same time.

8. Environmental Countermeasures
8.1. Noise and Vibrations
(a) Noise and vibration during construction should be limited, based on environmental
standards. Equipment (facilities) is needed to reduce noise and vibration.
(b) If complaints are received, quickly take measures as follows:
A. Use low noise, low vibration techniques and machines
B. Adjust or limit working times
C. Install soundproofing walls and materials which absorb vibration

GECOL Sept. 15, 2008

14 /18 Version 1.0
 Guidelines for Substation Construction

8.2. Water Contamination

(a) Because concrete and Bentonite liquid are alkali, pH management shall be performed
to neutralized acidity.
(b) When draining water mixed with oil, drain the water after removing oil by using a
separation tank or filter.

8.3. Land
(a) The land needed for construction is to be minimized. The scope, area and use of the
land shall be approved by land owners and government officials.
(b) When land is damaged, quickly restore it to its original condition.

9. Post-Construction
(a) When closing down a construction site, workers shall rearrange construction site to
its original condition.
(b) When closing down a site a long time before construction work finishes, take special
care not to leave hazards (which could cause accidents) for future users of the land.
(c) The construction site manager shall check the status of readjustments.
A. Clean and rearrange construction site
B. Restore warehouse and material piling sites to their original condition.

GECOL Sept. 15, 2008

15 /18 Version 1.0
 Guidelines for Substation Construction

Appendix 1. Safety Inspection(General)

<Table > Safety Inspection (General)

Safety Inspection
Project Supervisor

Contractor Site Engineer

Date Site

Checking Item Sup. Con. Remark

In the switchyard, be careful of electric shock

and commence the work after preparing
1 adequate arrangements like wearing safety
device and installing safety fences, warning
lights and so on.
Site engineer subdivides work schedule into
2
daily one and makes the safety plan.
Carefully review the work plan if there is a
3
possible risk.
Attach indication and plate of equipment to be
4 always viewable to prevent mistakes in
operating equipment.
If there is any problem in equipment while
5 working, report it to site engineer immediately
and follow his direction.
When using heavy machinery, secure the
insulation distance between machinery and
6
charged equipment and arrange extra supervisor
for watching.
Supervisor Name : (Signature)
Contractor Name : (Signature)

GECOL Sept. 15, 2008

16 /18 Version 1.0
 Guidelines for Substation Construction

Appendix 2. List of Safety Equipment

<Table > List of Safety Equipment

No List of Safety Equipment Pictures Reference

① Safety helmet All workers

All workers
② Safety belt who work on
the tower

③ Safety shoes All workers

④ Safety gloves All workers

⑤ Working clothes All workers

One set per

⑥ Emergency remedy
work site

GECOL Sept. 15, 2008

17 /18 Version 1.0
 Guidelines for Substation Construction

Appendix 3. List of Tools and Equipment

<Table > List of tools and equipment

Tools and
No Pictures and Spec
Equipment

Torque Wrench

Spanner

Wrench
(one side
type)

GECOL Sept. 15, 2008

18 /18 Version 1.0