IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 54, NO.
1, JANUARY/FEBRUARY 2018
Conversion of 230 kV Switchyard to Gas-Insulated
Substation in a Gas Plant
Merwyn D’Souza , Senior Member, IEEE, Saud Al-Shammari, and Mghwar Safwa, Member, IEEE
Abstract—Frequent failures and increased maintenance in a 30-
year old 230 kV air-insulated switchyard (AIS) of a large gas
plant caused the existing installation to be unreliable to provide
uninterrupted power supply to critical plant operations. The re-
placement parts from original equipment manufacturers became
scarce and expensive. The maintenance activities in severe and
extremely hot middle-east weather conditions were cumbersome
and time-consuming. A planned plant expansion with consider-
able incremental load to the facility provided an opportunity for
a review of the complete electrical system. After a thorough re-
view, it was decided to convert the main outdoor AIS to an indoor
gas-insulated switchgear (GIS) substation to support the existing
and new facilities. However, a total loss of power to the continuous
operation of this critical gas facility was unacceptable. The existing
switchyard with an energized 230 kV open bus system had limited
space to safely perform the demolition and construction activities
for the new GIS. Detailed analysis of the installation options, con-
struction techniques, safety requirements, and logistical methods
was performed to eliminate potential for any total loss of power.
The construction activity involved interfacing with two separate
redundant power supply sources, with separate transmission line
protection systems and equipment. The parties involved worked
together in reaching an agreement on engineering, procurement,
installation, testing, and commissioning activities that would suc-
cessfully implement this transition without any loss of power to the
gas production facilities.
Index Terms—230 kV, air-insulated switchyard (AIS), demoli-
tion, gas-insulated switchgear (GIS), installation options, transi-
tion, total loss of power.
I. BACKGROUND
HE EXISTING 230 kV air-insulated switchyard (AIS) lo-
T cated in a large gas plant in Saudi Arabia has been in
operation for more than 30 years. The existing equipment has
been experiencing increased maintenance for several years due
to equipment aging and lack of a robust system to withstand the
harsh middle-east desert weather conditions. Moreover, replace-
ment parts from original equipment manufacturers (OEMs) are
not easily available and supported raising safety concerns. These
Manuscript received June 23, 2016; accepted September 27, 2016. Date of
publication September 12, 2017; date of current version January 18, 2018.
Paper 2016-PCIC-0562, presented at the 2016 Petroleum and Chemical Industry
Conference, Philadelphia, PA, USA, Sep. 19–22, and approved for publication
in the IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS by the Petroleum
and Chemical Industry Committee of the IEEE Industry Applications Society.
(Corresponding author: Merwyn D’Souza.)
M. D’Souza and M. Safwa are with WorleyParsons, Monrovia, CA 91016
USA (e-mail: Merwyn.D’Souza@WorleyParsons.com; mghwar.safwa@worley
parsons.com).
S. Al-Shammari is with Aramco Services Company C/O Worley Parsons,
Monrovia, CA 91016 USA (e-mail: saud.shammari@aramcoservices.com).
Digital Object Identifier 10.1109/TIA.2017.2752143
0093-9994 © 2017 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications standards/publications/rights/index.html for more information.
895
operational and maintenance challenges of the 230 kV switch-
yard are a major concern in maintaining continuous production
in the gas plant. Any event that would result in a complete loss of
power would be environmentally disconcerting and financially
impairing. The existing plant will undergo a major expansion,
necessitating the addition of four more 230 kV bays to the exist-
ing switchyard to feed the new loads. The end user has analyzed
the ongoing operational problems of the 230 kV system and has
determined that a new indoor 230 kV gas-insulated switchgear
(GIS) would eliminate the concerns and be able to supply the
combined loads much more efficiently and reliably.
The existing switchyard is fed by radially connected, double
circuit, 230 kV overhead transmission lines (OHTL) from two
different sources. Each radial feeder is connected to a differ-
ent bus within the same sourcing substation. The main power
source is from the utility-owned power station that is connected
to the national grid via 230 kV OHTLs. The alternative power
source is from a cogeneration plant. All four incoming 230 kV
OHTLs terminate at the gantries within the 230 kV switchyard
of the gas plant. These gantries form the interface points be-
tween the incoming OHTLs and the gas plant electrical system.
No modifications are envisioned on the utility-owned 230 kV
OHTLs. The project was tasked with determining the optimum
method to connect the gantries to the new 230 kV GIS consid-
ering the existing structures, foundations, and clearances based
on a detailed study and site survey. The OHTL control, protec-
tion, and monitoring panels for all incoming lines are currently
located in the main substation P1. All control, protection, and
control cables to existing coupling capacitor voltage transform-
ers (CCVTs), disconnect switches (DSs), ground switches, and
transformers are required to be reconnected to the new 230 kV
GIS substation. The project is required to determine if these
existing panels could be utilized or new ones are to be installed.
The existing three 13.2 kV double-ended substations (P1, P2,
and P3) receive power from the 230 kV/13.2 kV step-down
transformers. The transformer 230 kV bushings are connected
to the 230 kV tubular bus system via DSs. These existing trans-
formers need to be fed from the new GIS substation. All related
control, protection, and monitoring cables need to be rerouted
or new ones to be installed from the existing equipment to the
new GIS substation.
The cogeneration power plant is connected to the national
grid via the gas plant with all surplus cogeneration power
being exported. This paper will address the constructability,
maintainability, and operability of revamping the existing elec-
trical system to maintain the gas plant operations at optimum
896 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 54, NO. 1, JANUARY/FEBRUARY 2018
Fig. 1. Existing 230 kV air-insulated switchyard.
Fig. 2. Existing 230 kV air-insulated switchyard.
production levels throughout the demolishing, construction,
testing, and commissioning activities. The major objective shall
be to perform all activities in a safe and reliable manner with
minimum disruption of power supply to the plant existing power
distribution systems.
II. EXISTING AIR-INSULATED SWITCHYARD
The existing 230 kV AIS consists of outdoor SF6 circuit
breakers (CB), DSs, grounding switches in an inverted post-
insulator configuration as shown in Figs. 1 and 2. The double
bus bar arrangement consists of rigid aluminum tubular buses
and is interconnected to the 230 kV outdoor equipment and
incoming A-frame gantries by aluminum-clad steel-reinforced
aluminum conductors.
The existing plant facility power consumption is an average
of 210 MW and a maximum of 238 MW. The cogeneration
power plant has three generation trains with a total capacity of
475 MW. An islanding and load shedding system (ILS) located
at substation P1 monitors the power flow from the cogeneration
Fig. 3. Planned GIS substation.
plant and the utility. The ILS initiates load shedding in the gas
plant in case of a total loss of power from the utility supply.
The group-operated DSs that are utilized to isolate the SF6
outdoor CBs have been problematic due to malfunctioning
mechanisms. The outdoor tubular buses and their supporting
insulated bushings need frequent maintenance and are a safety
concern in the intense heat and dusty environmental conditions.
III. PLANNED GAS-INSULATED SWITCHGEAR
The planned 230 kV GIS substation shall consist of indoor-
type, double-bus, single-breaker, SF6 GIS. The conceptual con-
figuration for the proposed substation is shown in Fig. 3. The
230 kV interface gantries shall be connected to the GIS incomers
by underground cables or above grade gas-insulated bus (GIB).
The GIS line up will contain two incoming circuits from cogen-
eration power plant, two incoming circuits from national grid
utility, two bus coupling, and two sectionalizing CBs as part
of the main bus arrangement. Feeder CBs will be connected
to the various loads as per project requirements. Each 230 kV
incoming or outgoing circuit can be connected to either one of
the two buses in one section. Each incoming/outgoing circuit
bay will be comprised of bus sections, disconnect/grounding
switches, power CBs, current transformers, surge arresters, and
termination bushings.
Protection, metering, and control systems consist of intelli-
gent electronic devices (IEDs) that are integrated with the power
system automation system (PSA) and perform protective relay
functions such as breaker failure protection, low impedance bus
differential protection, line differential protection, synchroniz-
ing check relays, as well as integration with the supervisory
control & data acquisition (SCADA) system. As the IEDs are
interfaced through the PSA interface, there is a much greater
availability of automation, monitoring, and control in the new
GIS. A 125 Vdc system will be installed within the new GIS
substation building to provide power to the GIS protection,
metering, and control systems. The physical location of this
D’SOUZA et al.: CONVERSION OF 230 KV SWITCHYARD TO GAS-INSULATED SUBSTATION IN A GAS PLANT
substation is to be optimized based on detailed site survey for
space availability and constructability.
IV. AIR INSULATED VERSUS GAS INSULATED
A brief discussion on AIS and GIS is essential in understand-
ing their application. The differences, advantages, and disadvan-
tages of AIS and GIS are discussed in the following paragraphs.
A. Air-Insulated Substation
AIS has all switchgear equipment, CBs, DSs, grounding
switches, busbars, and other related equipment installed out-
doors exposed to the atmosphere. Due to this condition, the AIS
infrastructure and components are always vulnerable to contin-
uous degradation in the harsh climate conditions.
B. Advantages and Disadvantages of AIS
The AIS is best suited for voltages below 230 kV. It requires a
larger space for installation, commissioning, and maintenance.
However, the equipment can be spaced liberally without any
appreciable increase in cost. The cost of construction and in-
stallation is lower due to its outdoor location, easily sourced,
and simpler equipment. It is also easier to extend in the future,
provided ample space is available. The AIS equipment is within
view, and therefore fault location and repair is easier.
The disadvantages include utilization of more space than GIS.
Regular and more frequent maintenance is required compared
to GIS, therefore resulting in higher maintenance costs. The AIS
is vulnerable to faults due to outdoor pollution, saline environ-
ment, and other factors such as direct lightning strikes, heavy
winds, rains, and cyclones. Due to these effects, the AIS have
lower reliability than GIS. Exposed live parts make working
around the equipment unsafe for attending personnel. It is nor-
mally not installed in densely populated areas and is vulnerable
to human intrusion.
C. Gas-Insulated Substation
The GIS has the high-voltage (HV) buses, CBs, switches,
current transformers, voltage transformers, and surge protec-
tors encapsulated within the metal enclosure containing sulfur
hexafluoride (SF6 ) gas. GISs primarily use SF6 gas as the pri-
mary insulating medium. SF6 is nontoxic, maintains atomic and
molecular properties even at high voltages, and has high cool-
ing properties and superior arc quenching properties. It is about
five times as dense as air. SF6 is used in GIS at pressures from
400 to 600 kPa absolute. The pressure is chosen so that the SF6
will not condense into a liquid state at the lowest temperature
(with dew point at or below –35 ˚C) the equipment is subjected
to. The switchgear housings are made of nonmagnetic material
such as aluminum or stainless steel. Its multicomponent units
make it very compact in size and highly reliable. The GIS has
a gas detection system that monitors the gas pressure in each
individual compartment.
897
D. Advantages and Disadvantages of GIS
The GIS is suitable for a large range of voltages due to its
compact size and modular design that provides flexibility for
many different configurations. The GIS needs less space than
the AIS (approx. 10% of AIS). Assembly and commissioning at
site is quicker due factory pre-assembly and testing. Segregated
and enclosed live parts make it a very reliable system (due to
reduced disruption of the insulation system). The contact with
the grounded metal enclosure is safer for attending personnel.
GIS has lower maintenance frequency and costs due to totally
enclosed elements. It also has a much higher reliability than
AIS. It can be installed indoors or outdoors in densely popu-
lated areas, in areas with heavy rainfall, sandstorms, or snow,
including underground and offshore locations. Environmental
factors such as high humidity, salinity, industrial pollution have
no major impact on the GIS. With proper maintenance, the op-
erational life of a GIS is estimated to be 40–50 years, compared
to 25–30 years for AIS.
The choice between GIS and AIS depends on their pros and
cons. Depending on their application, for many projects around
the world, GIS offers the obvious choice due to its technological
and economic advantages over AIS.
V. DESIGN
A. Design Criteria
The end user requirements mandate an elevated building
to house the new 230 kV GIS equipment. The GIS shall be
built to utility agency’s requirements that contain International
Electro-technical Commission’s (IEC) specifications. These in-
clude IEC 62271-1 [1], IEC 62271-100 [2], IEC 62271-102 [3],
and IEC-62271-203 [5].The new GIS substation shall contain
all related auxiliary equipment to protect, control, and moni-
tor the switchgear, incoming power supplies, OHTLs, feeders
connected to downstream equipment at existing 13.2 kV sub-
stations P1, P2, and P3; and new 13.8 kV substation P5. The
new GIS will interface with the existing ILS located in existing
substation P1.
The 230 kV incoming gantries shall be the interface point for
the OHTLs from the two power supply sources to the GIS. The
location of the GIS substation building P4 shall be based on the
option selected to connect the OHTLs to the GIS. All activities
involved in the conversion from AIS to GIS shall be conducted
in a manner that will sustain the continuity of power supply to
the existing plant to operate at full capacity.
Repurposing and expanding the existing switchyard ground
grid for the GIS required utilizing IEEE Std. 80 [7] and software
that performed analysis on the ground grid utilizing the finite
element method. Recommendations were made to upgrade the
grid to maintain the step and touch potentials within acceptable
safe limits under normal and fault conditions.
B. Interface Requirements With 230 kV Power Supply Sources
The OHTL protection, control, and monitoring panels for
the two power supply sources (cogeneration and utility) are lo-
cated in existing substation P1. These panels are connected to
898 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 54, NO. 1, JANUARY/FEBRUARY 2018
Fig. 4. 230 kV line differential protection.
existing CCVTs, current transformers (CTs), and potential trans-
formers (PTs), interlocking and signaling contacts located in the
AIS equipment. They also control the outdoor SF6 breakers and
their related DSs. These panels contain redundant multifunc-
tion protection relays for each circuit and must be in operation
while the OHTLs are energized to supply power to the gas plant.
The cables connecting the various AIS devices to these control
panels are installed underground within the switchyard area.
Relocating the existing panels and reutilizing them in the new
GIS substation was evaluated for constructability. The reloca-
tion effort was found to be too complicated and risky, rendering
the existing electrical system susceptible to shut down. Recom-
mendations were made to procure and install new control panels
in the new substation P4.
The planned GIS will contain the same functional elements
as the AIS, but will be enclosed in a compartment, making
the interface with different signals more localized. The power
supply incomers will be connected to the GIS. The incoming
power monitoring will be done at the GIS, but needs to be
interfaced with the ILS located in existing substation P1.
C. 230 kV Transmission Line Protection Requirements
The cogeneration OHTLs are protected by dual primary
microprocessor-based type line differential relays as shown in
Fig. 4. The communication channels between the relays on the
sending and receiving sides are achieved via fiber optic cables
(OPGW) and set of interface converters. The utility-owned
OHTLs are protected by dual primary electronic type impedance
line distance relays (Mho) and set of interface convertors. The
communication channel between the distance relays on both
the sending and receiving ends of the lines was achieved via
line trap and pilot wires when they were initially installed.
However, since then the line trap-pilot wire communication
system has been upgraded to fiber-optic ground-wire (OPGW).
An additional backup line protection is also provided with
time phase over-current, ground fault, UV/OV, and frequency
relay protection. The protection philosophy limits the use of
automatic reclosing and line restoration in line fault scenarios,
locking out the line until there can be a physical verification
of the line’s integrity. It does not discriminate between single-
or three-phase faults (i.e., no single pole tripping). Status and
alarm signals are provided to the central power monitoring
system through a remote terminal unit.
The 230 kV OHTL protection scheme was evaluated and
recommendations were made to procure new protection pan-
els and update their existing device settings to meet new
microprocessor-based relay requirements based on IEC 61850
[4]. The new protection scheme will be capable of communicat-
ing with the PSA and other equipment connected to the system.
The new panels and protective relaying devices were selected to
meet the requirements and agreed upon with the utility agency.
The new multifunction digital line differential relays shall pro-
vide a simple built-in interface to fiber optic communications
based on IEC 61850 [4]. In addition to line differential pro-
tection, they will include additional functions such as phase
and ground distance elements, directional and nondirectional
overcurrent elements, synch check, voltage elements, frequency
elements, and general purpose logic. Two sets of digital line dif-
ferential relays must be used, each with dedicated sets of CTs
and separate optical fibers for communication. Relays shall be
reliability proven and be from two different manufacturers.
The protection scheme for the feeders from the AIS to the
existing substations P1, P2, and P3 was at a short distance (less
than 200 ft.) and only utilized overcurrent relays. However, the
distance between the GIS and substations P1, P2, P3, and P5 is
not insignificant, and after evaluating potential fault scenarios,
the recommendation was made to utilize line differential pro-
tection for the feeders. In addition, a communication interface
will be established between the GIS and the feeder substations
to coordinate relay protection.
D. 230 kV Tie-In to GIS
A study was conducted to evaluate the best option to connect
the incoming 230 kV OHTL power sources to the GIS via the
existing gantries. The options were as follows:
1) 230 kV GIB;
2) cross linked polyethylene (XLPE) insulated cables;
3) hybrid of GIB (for incoming lines) and XLPE cables (for
outgoing feeders).
The GIB requires above grade structural steel framework with
a concrete foundation to route the 8-in diameter buses per phase.
Installation of six circuits with three-phases per circuit is very
cumbersome and unsafe in an energized switchyard. The coor-
dination between demolition of existing AIS and construction of
the new GIB would not be feasible without prolonged shutdown
of the 230 kV switchyard.
Installation of 230 kV underground cables was carefully an-
alyzed taking into consideration the required minimum sep-
aration between phases and between circuits. Assessment in-
D’SOUZA et al.: CONVERSION OF 230 KV SWITCHYARD TO GAS-INSULATED SUBSTATION IN A GAS PLANT
cluded the maximum current carrying capacities of individual
circuits under contingency conditions, including the ability of
one 230 kV utility circuit to carry the plant load (that includes
existing, planned, and future loads). Thermal capacity calcula-
tions for directly buried XLPE cables were performed to select
adequate conductor size for safely transmitting the maximum
power to existing and future demand load that the plant is ex-
pected to consume.
A comparison of these two options included equipment costs,
lead time, constructability, and reliability. The lead time for
cables is about half the lead time for GIB. The installation
time is about the same. However, the AIS tubular structures
in close proximity need shutdown and demolition to facilitate
installation of GIB structures. The GIB needs manufacturer’s
supervision during installation and commissioning. The GIB
foot print will require a significant portion of the switchyard
plot and will limit future expansion. The XLPE cables have
the lowest cost, shorter lead time, and an equivalent overall
reliability and maintainability when compared with GIB. The
XLPE cables have the lowest risk to project time line. The
XLPE cables have a clear advantage based on constructability
and costs. Based on the results of the study, the end user decided
to proceed with the underground XLPE power cable option to
connect the 230 kV OHTLs and the load feeders to the GIS.
VI. POTENTIAL RISKS AND MITIGATION
The 230 kV AIS conversion to GIS is a complex undertaking
involving interface with many entities. The most significant risks
include the following.
1) Interference of underground cabling with existing
underground utilities: The construction drawings shall be
followed to ensure that specified safety clearances and
separation between circuits are maintained. Any modifi-
cations to existing utilities shall be coordinated and carried
out in a timely manner.
2) Coordination of demolition, installation, and transition
activities for uninterrupted plant operation: The plant
operations need to perform the necessary configuration
of existing electrical equipment to isolate the electrical
lines and equipment during demolition and tie-in activi-
ties. This will require a comprehensive list of motors and
loads that need to remain energized during the transition
process, considering operation from a single-ended bus
in all existing substations. A detailed procedure must be
prepared, agreed upon, and approved to implement these
activities.
3) Modifications to existing 230 kV incoming A-frame
gantries to terminate the new underground cables need
removal of existing CCVTs and replacement of surge ar-
resters. The cable terminators will need their own struc-
ture with new foundations. The 230 kV cable termination
is a specialized activity that must be carefully planned
and coordinated with the cable terminator manufacturers.
Testing and inspection of this interface involves multiple
entities and may add significant time to each activity.
899
4) All personnel risk and safety factors related to working
within an energized 230 kV switchyard were evaluated
based on ANSI/IEEE C2-2012, National Electrical Safety
Code (NESC) [6], and recommendations made to be incor-
porated into the project constructability and safety plans.
Substation modifications and new expansion buildings have
been limited to areas within the security fence lines and do not
present any appreciable security risk.
VII. PATH TO EXECUTION
A. Project Requirements
The project requirements include the design, materials, fabri-
cation, inspection, testing, commissioning, and documentation
based on end user requirements. Compliance to end user spec-
ification requires all electrical equipment to be installed as per
NEC (NFPA 70) [12]. The reinforcement bars in GIS substa-
tion foundation shall be connected to the grounding grid at two
locations to act as additional ground rods. To avoid damage to
reinforced concrete foundation, the actual current in steel bars
must be less than the value of short time current loading ca-
pability ICE of the concrete enclosed electrode, calculated as
per IEEE Std. 80 [8], and clause 14.6. Safety measures as per
IEEE Std. 80 [8] shall be taken to limit the undesirable effects
caused by circulating currents and transient grid potential rise.
Insulation coordination study of the GIS shall be performed to
ensure adequacy of protective margin considering power fre-
quency over voltages, switching over voltages, lightning over
voltages, and very fast transients.
The cable installation shall be a combination of direct-buried
and concrete encased duct bank in a single layer arrangement
as per end user standard details. All cable risers shall be ad-
equately supported. The GIS incoming 230 kV cables shall
terminate outdoors at the incoming gantries, and indoors at the
GIS through elevated building floor. The cable risers shall be
adequately protected by steel structural supports.
All 230 kV GIS cable terminations shall be done under manu-
facturer’s supervision utilizing personnel certified in accordance
with manufacturer’s procedures. The 230 kV cable termination
installation and testing shall follow the guidelines in IEEE 1300
[11] and IEEE 48 [13], respectively.
B. GIS Testing
The end user, their engineer, the OEM, and the third party
inspector shall witness the specified tests of the GIS at the man-
ufacturer’s facilities. The factory testing confirms functionality,
operability, and reliability of the design. It also establishes the
baseline data and that the switchgear is suitable for the speci-
fied application. Routine tests shall be as prescribed in relevant
standards and shall include partial discharge tests on all PTs, de-
termination of knee point voltage (VK ), and excitation limiting
secondary voltage (UAL ) on CTs.
C. Cable Testing
The field testing of HV power cable along with all acces-
sories ensures capability to meet design requirements, detect
900 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 54, NO. 1, JANUARY/FEBRUARY 2018
damages during shipping and installationand defects or er-
rors in workmanship in splices and terminations. Since the
installation will be directly buried, cable tests shall be performed
with a minimum 150 mm backfill cover over the cables. The test
site shall have proper protective barriers and warning signs as
per company safety procedures. Cables testing shall include con-
ductor continuity and phasing tests with minimum of 1000 Vdc;
insulation tests prior to and after performing the HV tests; cable
profile test by radar prior to HV test; HV ac tests at 20–300 Hz
frequency with pure sine-wave shape voltage with test voltages
selected as per IEC 60840 [14]; cable jacket test to confirm in-
tegrity of outer jacket; cable impedance measurement for relay
setting determination; and conductor and shield resistance tests.
D. Site Acceptance
The GIS equipment shall be installed, all interconnections be-
tween various interfaces completed and inspected prior to final
functional check out. Site acceptance is required to establish that
the electrical equipment is safe, free of electrical shock and fire
hazard, and suitable for the purpose for which it is intended to
be used. The high voltage ac (HVac) system shall be tested and
operational prior to performing any testing on the GIS and pro-
tective relay panels. All visual, mechanical, and electrical tests
shall be performed as per end user’s specifications. The GIS test-
ing shall be performed as per IEC 62271-203 [5]. All functional
checks for GIS operation; alarm, interlocking, indication from
GIS to local, and remote control panels shall be performed.
The utility requires a confirmation letter from the end user
that all tests required as per their construction standards have
been completed and documented. All deficiencies found shall
be documented and categorized in the deficiency register. All
deficiencies shall be corrected prior to energization. A joint
final inspection shall be carried out to confirm compliance with
interface requirements as per the memorandum of understanding
between the end user and utility. After successfully meeting
the utility and end user requirements, the installation shall be
signed off by the inspection group and Readiness of Energization
Report approved for energization.
VIII. TRANSITION PLAN
The conversion from existing AIS to new GIS involves careful
planning of demolition, construction, testing, and re-energizing
activities. This section addresses the various issues involved
with the coordination of demolishing the existing electrical
equipment with its associated structures and the installation
of new equipment, structures, supports, various cable trenches,
and ducts in a safe manner.
Failure to plan and to obtain prior approvals or agreements
with the involved parties will cause major delays in the seam-
less transfer of power supply from the AIS to GIS. Dismantling
or demolishing of existing structures/equipment in the 230 kV
switchyard shall be performed concurrently with the installation
of new 230 kV XLPE cables and cable terminators (including
its associated steel structures). The installation contractor shall
submit a risk assessment report prior to performing any work
within the switchyard. All work will be performed with por-
tions of the 230 kV switchyard equipment energized in order
to maintain plant operations. Preventative safety measures must
be followed during construction works to avoid any loss of life,
property, and gas production.
The 230 kV OHTL connection to the GIS shall follow the
following sequence:
1) utility line-A;
2) utility line-B and cogen line-2;
3) cogen line-1.
Prior to commencing any work, the following steps shall be
taken to ensure complete understanding of the construction work
process and execution methods.
A. Preparatory Activities and Safety Planning
1) Approved work permit shall be obtained as per end user
procedures.
2) All detailed drawings, documents, and vendor data per-
taining to 230 kV switchyard/GIS shall be final and is-
sued for construction.
3) All new equipment and materials required for installa-
tion shall be readily available at the site complete with
installation, testing, and operating procedures.
4) All test forms and procedures shall be available prior to
the scheduled activities.
5) Existing conditions at the 230 kV switchyard and 13.2 kV
substations P1, P2, and P3 shall be verified prior to ini-
tiation of any work.
6) Construction of new substations P4 and P5 shall be me-
chanically complete and ready for energization.
7) The existing switchyard grounding grid shall remain in
place and shall be extended to cover the substations P4
and P5. All temporary grounding systems shall meet
IEEE Std. 1246-2011 [10].
8) Installation of new control, metering, protective relay
panels, and communication interfacing devices related
to 230 kV OHTLs shall be mechanically complete and
ready for commissioning and start-up.
9) 230 kV cable feeders and the intertrip control wires at
both sides of new substations P4 and P5 shall be installed,
tested, and terminated.
10) All protection, control, metering, signal, load shedding,
and communication cables within GIS substation P4;
and between GIS and existing 13.2 kV and new 13.8 kV
substations shall be installed, tested, and ready for
termination.
11) Testing and precommissioning of all equipment and pro-
tective devices within substations P4 and P5 shall be
carried out and accepted by the end user.
12) Cable trenches shall be prepared and ready for installa-
tion of 230 kV XLPE cables and associated protection
and communication cables from GIS building to utility
lines A and B, and cogeneration lines 1 and 2.
13) The new 230 kV cables and associated communication
cables related to OHTL protection and 230 kV cable
feeders from GIS to existing substations P1, P2, and P3
shall be partially installed and coiled at a safe distance
D’SOUZA et al.: CONVERSION OF 230 KV SWITCHYARD TO GAS-INSULATED SUBSTATION IN A GAS PLANT
Fig. 5. Utility line-A and cogen line-2 de-energized.
near the existing interface gantry structures as shown on
construction drawings.
14) All dismantled materials shall be stored at a clean
and safe location and delivered to end user’s ware-
house/storage.
15) Manpower and tools pertinent to the planned activities
shall be available. Measuring and testing devices shall
be calibrated prior to any activities.
16) Lock out/tag out (LOTO) procedures as per NFPA 70E
[12] and NESC [6] safety codes and recommendations
shall be followed on activities that involve disconnection
of energized equipment. All elements of control shall be
actively in place. In addition, the safety precautions on
hazards which must be controlled shall be followed as
per approved work permit.
17) Barricades/barriers and safety signs shall be installed
as per end user safety procedures prior to commence-
ment of construction activities. NFPA 70E [12] Table
130.4(D)(a) lists the limited approach boundary as 4.0 m
(13 ft.) and restricted approach boundary as 1.7 m (5 ft. 8
in) for 230–242 kV phase-phase alternating current (ac)
systems.
18) All construction personnel shall be qualified for the tasks
and wear proper personal protective equipment when
working in the vicinity of energized equipment.
B. Transition Plan for Utility Line-A
1) Isolate/de-energize utility line-A and cogen line-2. See
Fig. 5.
2) Disconnect CCVTs from 230 kV utility line-A gantry,
vertical drop-bus on phases A, B, and C.
3) Disconnect all power, control cables, and metal
frame grounding wires in the CCVT junction boxes,
switchgears, protective devices, metering, and load shed-
ding panels related to utility line-A equipment.
901
4) Remove CCVTs pertaining to phases A, B, and C of
utility line-A.
5) Install foundations, steel structures, and 230 kV XLPE
cable terminators at utility line-A gantry.
6) Dismantle 230 kV horizontal tubular-bus between utility
line-A gantry and D706.
7) Remove CB A702 and DS D706, D707, and D724.
8) Remove/demolish all related control wires, conduits,
junction boxes, steel structures, concrete foundations,
and communication interfacing devices.
9) Perform all necessary cable testing before connecting to
utility circuits.
10) Connect 230 kV cables to utility phases A, B, and
C of line-A gantry through cable terminators and bus
drops. Also, connect pilot wires from utility gantry
to line protection equipment in GIS as shown on
drawings.
11) Ensure structural steel frame of all new structures and
equipment metal frame are connected to the substation
ground grid.
12) Ensure all incoming and outgoing feeder breakers on
230 kV GIS are de-energized and LOTO has been
achieved. The bus-sectionalizer and bus-coupler break-
ers shall remain open.
13) Connect 230 kV cables to the new 230 kV incoming
breakers.
14) Perform testing on OHTL protection, control, and com-
munication systems.
15) Dismantle conductors/ horizontal tubular bus sections
among D706, D707, and D712. Demolish steel structures
and foundations of all related supports.
16) Dismantle conductors/tubular bus sections between
D724 and D716 including any extensions to D712 and
D714.
17) Remove DS D706, D707, D712, D714, D716, and D724.
Demolish associated foundations and structural sup-
ports.
18) Install foundations, steel structures, and 230 kV XLPE
cable terminators at T702, T704, and T706 interface
gantries.
19) Perform all cable acceptance tests prior to connecting
the cables to cable terminators at T702, T704, and T706
interface gantries.
20) Install all necessary cables and wires associated with pro-
tective devices, control, load shedding system, commu-
nication, and PSA between the new GIS and CB control
panels in existing and new 13.8 kV substations. Caution
shall be exercised and all connections shall be made only
on de-energized equipment.
21) Test all monitoring, control, and communication circuits
related to existing transformers T702, T704, and T706
for continuity and functionality.
22) All exception items related to this activity shall be closed.
23) Energization package shall be submitted along with en-
ergization form.
24) Interface to SCADA system shall be in operation.
902 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 54, NO. 1, JANUARY/FEBRUARY 2018
Fig. 6. GIS energized via utility line-A.
25) Prior to energizing utility line-A, ensure synchronizing
check relays on utility line-A and cogen lines 1 and 2 are
active and working correctly.
26) Energize utility line-A, and monitor incoming cable from
gantry to GIS incomer CBs for 24 h. Confirm safe oper-
ation.
27) Energize incoming breaker on GIS connected to utility
line-A circuit. The GIS shall be hot soaked for 24 h, or
as per vendor recommendation prior to energizing any
other GIS breaker.
28) Verify that the sync-check relays on GIS bus coupler and
sectionalizing breakers are active and working correctly.
Close bus coupler breaker to energize GIS bus 1A.
29) Monitor GIS control, communications, and protective
devices for any unusual operational issues under un-
loaded conditions.
30) Energize 230 kV GIS feeder breakers to new transform-
ers T707 and T708. Ensure all transformers are operating
normally and are ready for loading.
31) Close the main incomers on 13.8 kV switchgear at new
substation P5 and monitor for safe operation.
32) Energize 230 kV GIS feeder CBs to existing transform-
ers T702, T704, and T706. Ensure all transformers are
operating normally and are ready for loading.
33) Ensure synchronism is achieved between utility and
cogen line-1. Close bus-2 main incoming breakers on
13.8 kV switchgears in substations P1, P2, and P3 (B303,
B304, B370, and B391). Now, all switchgears are oper-
ating in parallel with three (3) sources of power supplies
(from utility line-A, utility line-B, and cogen line-1).
This will ensure continuity of power supply to UGP op-
erations without any interruption. See Fig. 6.
34) After energizing all 13.8 kV switchgear, monitor for safe
operation as per design.
C. Transition Plan for Utility Line-B and Cogen Line-2
1) Isolate/de-energize utility line-B and cogen line-2.
2) Disconnect CCVTs on utility line-B and cogen line-2 at
vertical drop buses on phases A, B, and C.
3) Disconnect all cables, wires, and pilot wires in the CCVT
junction boxes and switchgear terminals related to utility
line-B and cogen line-2.
4) Dismantle all junction boxes and conduits of the utility
line-B and cogen line-2 CCVTs. Store them in a safe
place.
5) Demolish CCVT related steel structures and foundations
related to utility line-B and cogen line-2.
6) Remove DS D704 and 230 kV horizontal tubular bus.
7) Install foundations, steel structures, and 230 kV XLPE
cables terminators at utility line-B and cogen line-2
gantries.
8) Continue the trenches and install 230 kV XLPE and
associated communication cables from GIS building to
utility line-B and cogen line-2 gantries. Also, install ca-
bles related to cogen line-1 in the same trench.
9) Perform activities as per steps 8–12 presented in
Section VIII-B for utility line-B and cogen line-2.
10) Connect 230 kV cables to the new 230 kV GIS incoming
breakers.
11) Perform testing on OHTL protection, control, and com-
munication systems.
12) All exception items related to this activity shall be closed.
13) Energization package shall be submitted along with en-
ergization form.
14) Interface to SCADA system shall be in operation.
15) Synchronize and energize utility line-B and cogen
line-2. Monitor incoming cables from the gantries to
GIS incomer CBs for 24 h. Confirm safe operation.
16) Energize GIS incoming breaker connected to utility line-
B and cogen line-2 circuits. Exercise bus-sectionalizer
and bus-coupler breakers for synchronism and function-
ality.
17) The 230 kV GIS will now be on double ended operation
via utility line-A, utility line-B, cogen line-2, and cogen
line-1 power supplies. See Fig. 7.
D. Transition Plan for Cogen Line-1
1) Isolate/de-energize Tihama line-1.
2) Disconnect all wires including OPGW in the CCVT junc-
tion boxes and switchgear terminals related to cogen
line-1.
3) Disconnect CCVTs on cogen line-1 from the vertical
drop bus on all phases A, B, and C.
4) Dismantle all junction boxes and conduits of the cogen
line-1 CCVTs. Store them in a safe place.
5) Demolish steel structure and foundations related to co-
gen line-1 CCVT.
6) Disconnect and remove all cables, control wires from
CTs, and power supplies in the junction box terminals
related to CBs A703 and A704; DSs D721, D722, and
D725.
7) Dismantle 230 kV horizontal tubular bus between cogen
line-1 gantry and D721 (including extensions to D725).
D’SOUZA et al.: CONVERSION OF 230 KV SWITCHYARD TO GAS-INSULATED SUBSTATION IN A GAS PLANT
Fig. 7. GIS energized via utility line-B and cogen line-2.
8) Dismantle 230 kV tubular bus between D722 and D715
(including extensions to D705, D711, and D713).
9) Remove CBs A701, A703, A704, and A705; and DSs
D705, D721, D722, D723, D725, D726, D711, D713,
and D715. Remove/demolish all related control wires,
conduits, junction boxes, steel structure, and concrete
foundations.
10) Install foundations, steel structures, and 230 kV XLPE
cables terminators at cogen line-1 gantry as shown on
installation drawing.
11) Prepare trenches and continue installation of 230 kV
XLPE and associated communication cables from GIS
building to cogen line-1 gantry.
12) Perform activities as per steps 8–12 presented in
Section VIII-B for cogen line-1.
13) Connect 230 kV cables to the new 230 kV GIS incoming
breakers.
14) Perform testing on OHTL protection, control, and com-
munication systems.
15) Continue trenching and install 230 kV XLPE cables from
GIS outgoing feeder CBs to 230 kV cable terminators at
D711, D713, and D715 interface gantries.
16) Install foundations, steel structures, and 230 kV XLPE
cable terminators at T701, T703, and T705 interface
gantries as shown on drawings.
17) Install all necessary cables and wires associated with
protective devices, control, load shedding system, com-
munication, and PSA between the new GIS and CB con-
trol panels in existing 13.2 kV substations. Caution shall
be exercised and all connections shall be made only on
de-energized equipment.
18) Perform all cable acceptance tests prior to connecting
the cables to cable terminators at T701, T703, and T705
interface gantries.
19) Test all monitoring, control, and communication circuits
related to existing transformers T701, T703, and T705
for continuity and functionality.
903
20) All exception items related to this activity shall be closed.
21) Energization package shall be submitted along with en-
ergization form.
22) Interface to SCADA system shall be in operation.
23) Prior to energizing cogen line-1, ensure synchronizing
check relays on GIS bus are working correctly.
24) Energize cogen circuit line-1 and monitor incoming ca-
ble from gantry to GIS incomer CB for 24 h.
25) Monitor GIS control, communications, and protective
devices for any unusual operational issues.
26) Energize 230 kV GIS feeder breakers feeding existing
transformers T701, T703, and T705. Ensure all trans-
formers are operating normally and are ready for loading.
See Fig. 3.
27) After energizing transformers T701, T703, and T705,
normalize 13.8 kV switchgear and monitor for safe op-
eration as per design.
28) The OHTL control and protection panels in the existing
substation P1 substation shall be removed or mothballed
after ensuring that the new 230 kV system in GIS build-
ing is operating safely.
IX. CONCLUSION
Conclusions drawn in this paper are based on past experi-
ence, good engineering practice, and proven construction meth-
ods. Careful planning with strong project management will be
required to execute this conversion. Procurement of engineered
equipment must start early during the detailed design phase. Site
preparation and remediation activities, if necessary, should be
completed to facilitate quicker installation of the substation and
underground utilities. Functional testing of all major equipment
at the factory shall be witnessed by the installation contractor
and end user to pre-empt any operational discrepancies. The
new GIS, all related auxiliary equipment, new OHTL protec-
tion, and control panels with all interconnection wiring shall
be installed, inspected, certified to be mechanically complete,
functionally tested, and ready to be energized, prior to shutdown
of any existing electrical equipment.
Since the construction activities of the power system transi-
tion from AIS to GIS need to be performed while the gas plant is
in operation, maintainability and reliability factors of all activ-
ities must remain high. Contingency scenarios were developed
and mitigating actions were approved by the end user to en-
able a safe partial or complete plant shutdown. These scenarios
considered immediate restoration of power supply to restart the
plant.
REFERENCES
[1] High-Voltage Switchgear and Controlgear: Common Specifications, IEC
Std. 62271-1, 2007.
[2] High-Voltage Switchgear and Controlgear: Alternating-Current Circuit-
Breakers, IEC Std. 62271-100, 2008.
[3] High-Voltage Switchgear and Controlgear: Alternating Current Discon-
nectors and Earthing Switches, IEC Std. 62271-102, 2001.
[4] Communication Networks and Systems for Power Utility Automation, IEC
Std. 61850, 2010.
904 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 54, NO. 1, JANUARY/FEBRUARY 2018
[5] High-Voltage Switchgear and Controlgear: Gas-Insulated Metal-
Enclosed Switchgear for Rated Voltages Above 52 kV, IEC Std. 62271-203,
2011.
[6] National Electrical Safety Code (NESC), ANSI/IEEE C2-2012, 2012.
[7] IEEE Standard for High Voltage Gas-Insulated Substations Rated Above
52 kV, IEEE Std. C37.122-1993, 1993.
[8] IEEE Guide for Safety in AC Substation Grounding, IEEE Std. 80-2013,
2013.
[9] IEEE Guide for Substation Fire Protection, IEEE Std. 979-2012, 2012.
[10] IEEE Guide for Temporary Protective Grounding System Used in Substa-
tions, IEEE Std. 1246-2011, 2011.
[11] IEEE Guide for Cable Connections for Gas-Insulated Substations, IEEE
Std. 1300-2011, 2011.
[12] National Electric Code (NEC), NFPA 70, 2014.
[13] Standard for Electrical Safety in the Workplace
R
, NFPA 70E-2015, 2015.
[14] Test Procedures and Requirements for Alternating-Current Cable Termi-
nations Used on Shielded Cables Having Laminated Insulation Rated
2.5 kV Through 765 kV or Extruded Insulation Rated 2.5 kV Through 500
kV, IEEE Std. 48-2009, 2009.
[15] Power Cables With Extruded Insulation and their Accessories for Rated
Voltages Above 30 kV (Um = 36 kV) Up To 150 kV (Um = 170 kV) – Test
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[16] M. D’Souza, S. Al Shammari, and M. Safwa, “Conversion of 230 KV
switchyard to gas insulated substation in a gas plant,” in Proc. 2016
Petroleum Chem. Ind. Tech. Conf., Philadelphia, PA USA, 2016, pp. 1–10,
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Merwyn D’Souza (M’85–SM’14) received the B.S.
degree in electrical engineering from the National In-
stitute of Technology Karnataka, India, in 1975.
He is currently a Senior Engineering Manager
with WorleyParsons, Monrovia, CA, USA. He au-
thored two IEEE Petroleum and Chemical Industry
Committee papers. He has been involved in mining,
oil, and gas industry major projects worldwide for
more than 30 years in various aspects of electrical
engineering design, procurement, construction, start-
up, and commissioning.
Mr. D’Souza is a registered Professional Engineer in the state of California.
Saud Al-Shammari received the graduate degree
in electrical engineering from the King Fahad Uni-
versity of Petroleum and Minerals, Dhahran, Saudi
Arabia, in 2001.
He has been with Saudi Aramco, Monrovia, CA,
USA, since 2002 and has led design reviews and
electrical power system commissioning activities on
mega power projects. He is in a supervisory position
with the Power Systems Engineering Department,
Saudi Aramco, and is currently on a project man-
agement assignment on mega oil and gas projects.
He has co-authored several published IEEE-International Conference on Har-
monics and Quality of Power articles.
Mghwar Safwa (M’05) received the B.S. degree in
electrical engineering from the University of Aleppo,
Aleppo, Syria, in 1989.
He is currently with WorleyParsons, Monrovia,
CA, USA, as a Technical Consultant in a supervisory
role. He has worked on electric power generation and
distribution projects for more than 20 years in project
management, design, start-up, commissioning, facili-
ties maintenance, and operations management capac-
ities. He has performed complex analytical studies
on onshore and offshore electrical systems on several
large projects worldwide.
Mr. Safwa is a member of the International Society of Automation.