Substation Design

Project plan

Team Number
SDMAY19-17

Client
Burns & McDonnell

Faculty Advisor
Craig Rupp

Team Members
Jake Heiller
Rebecca Franzen
Tom Kelly
Riley O’Donnell
Connor Mislivec
Wilson Pietruszewski

Team Email
sdmay19-17@iastate.edu

Team Website
https://sdmay19-17.sd.ece.iastate.edu/

Revised
09/27/2018 / Version 1.0
 Table of Contents
1 Introductory Material 4
1.1 Acknowledgement 4
1.2 Problem Statement 4
1.3 Operating Environment 6
1.4 Intended Users and Intended Uses 7
1.5 Assumptions and Limitations 7
1.6 Expected End Product and Other Deliverables 7

2 Proposed Approach and Statement of Work 8

2.1 Objective of the Task 8
2.2 Functional Requirements 9
2.3 Constraints Considerations 10
2.3.1 Constraints 10
2.3.2 Standards 11
2.4 Previous Work And Literature 11
2.4.1 Existing tools 11
2.4.2 Relevant Literature 11
2.5 Proposed Design 12
2.6 Technology Considerations 12
2.7 Safety Considerations 12
2.8 Task Approach 12
2.9 Possible Risks And Risk Management 14
2.10 Project Proposed Milestones and Evaluation Criteria 14
2.11 Project Tracking Procedures 14
2.12 Expected Results and Validation 14
2.13 Test Plan 14

3 Project Timeline, Estimated Resources, and Challenges 15

3.1 Project Timeline 15
3.2 Feasibility Assessment 16
3.3 Personnel Effort Requirements 17
3.4 Other Resource Requirements 19
3.5 Financial Requirements 19

4 Closure Materials 19
4.1 Conclusion 19
4.2 References 20
4.3 Appendices 22
List of Figures
Figure 1: Project Approach
Figure 2: Semester 1 Gantt Chart
Figure 3: Semester 2 Gantt Chart

List of Tables
Table 1: Tasks for Grounding and Lightning Studies Phase
Table 2: Tasks for Physical Design Phase
Table 3: Tasks for AC/DC Studies Phase
Table 4: Tasks for Controls & NIA Phase

List of Symbols

List of Definitions
IEEE: Institute of Electrical and Electronics Engineers
AC: Alternating Current
DC: Direct Current
SCADA: Supervisory Control and Data Acquisition
RTU: Remote Terminal Unit
NIA: Networks, Integration, and Automation
1 Introductory Material
1.1 Acknowledgement
The Substation Design team would like to thank Grant Herrman, Abeer Hamzah, and Brian
Obermeier, employees of Burns & McDonnell, for their willingness to oversee this project and
for serving the team as technical advisors. The Substation Design team would also like to Craig
Rupp, the faculty advisor for this project, for serving the team as a technical and professional
advisor..

1.2 Problem Statement

While electric power transmitted a long distance has a high voltage which reduces power losses
as electricity flows from one location to another, it is unsafe to distribute electricity at such a
voltage directly to consumers. Similarly, though the production capabilities of electric power
generators vary, electric power generators are incapable of generating electric power at
voltages necessary to transmit that electric power long distances.

General Purpose
For this reason, substations are necessary throughout power grids. The primary function of a
substation is to raise or lower the voltage of the electric power flowing into the substation. The
main piece of equipment located at a substation is a power transformer, an electromagnetic
apparatus capable of raising or lowering an input voltage, then transmitting electric power—at a
raised or lowered output voltage, relative to the input voltage—long distances or distributing it to
electricity consumers.

Substations also help to ensure the reliability of the power grid. Two other pieces of equipment
located at substations are circuit breakers and disconnect switches, which allow utilities to
isolate electrical equipment—including electrical-current-carrying lines—from the rest of the
power circuit/power grid should a fault occur somewhere in the power grid.

General Problem Statement

Burns & McDonnell has tasked the Substation Design team with designing a new, 138/69
kilovolt (kV) substation that will not be built, but that could theoretically “be used as an
interconnection for a new wind generation plant near Ames, IA.” (Specific Purpose)

General Solution Approach

The Substation Design team will need to do the following to complete this project:

1. Specifications:
Relay Panels – The Iowa State Senior Design team will create all relay panels including
protective relays.
2. Substation Layout:
The Iowa State Senior Design team will submit a substation layout—including substation
equipment, the control building, rigid bus, structures, and perimeter fence—based on the most
economical option, which allows for future expansion with maximum flexibility.

3. Bus and Insulator Sizing Design

The Iowa State Senior Design team will perform calculations using predicted fault levels
and weather criteria to establish the mechanical forces resulting at each of the substation
buses.

4. Ground grid
The Iowa State Senior Design team will utilize software provided by Burns & McDonnell
to design and analyze the grounding system. The grounding design will be consistent with IEEE
80 techniques, using a combination of ground mat and rods for arriving at acceptable step and
touch potential limits and resistance to remote earth.

5. Raceway
The Iowa State Senior Design team will design a conduit plan using a combination of
surface trenches, subsurface conduits, and equipment riser conduits.

6. Control Building
The Iowa State Senior Design team will prepare control building equipment layout
drawings for the substation. The control building will be sized to accommodate the 125V DC
battery and charger, AC & DC panels, SCADA RTU and all protective relay panels required for
the initial installation.

7. 125V DC Station Battery Design

The Iowa State Senior Design team will develop a battery design for the substation using
IEEE 485 techniques. Loads will be sized, including future loads, for the sizing of batteries,
chargers, and panels used in the 125V DC system. The time period for a station service outage
will be considered when arriving at the required battery size.

The Iowa State Senior Design team will submit a report which:

i. Clearly summarizes the design requirements

ii. Defines the calculations used
iii. Summarizes the results and recommended battery design

8. Relaying and Controls

The Iowa State Senior Design team will generate a one-line diagram, one 69kV circuit
breaker schematic, one 138kV circuit breaker schematic, one-line relay schematic, and the
transformer schematics.
9. Lightning Protection
The Iowa State Senior Design team will evaluate and design lightning protection for
complete station protection against direct lightning strikes in accordance with IEEE STD 998-
2012 Electro Geometric Model (EGM) using the empirical curves method.

The Iowa State Senior Design team will submit a report which:

i. Defines the calculations used in developing the layout of the lightning

protection
ii. Clearly summarizes the orientation and protection results for each grouping(s)
of shielding electrodes
iii. Summarizes the failure rate of the substation
iv. Provides a recommended configuration of the shielding electrodes which
includes the maximum effective heights of the lightning masts and shield wires.

10. Communications
The Iowa State Senior Design team will do the following:

i. Create a communications block diagram and design the substation

communications network using a combination of serial and ethernet
network equipment.
ii. Design microwave radio system for communications transport. This will
include frequency selection, tower sizing and placement.
iii. Provide equipment quotes and engineering cost estimate.
iv. Generate a SCADA points list from a provided template.
v. Configure the RTU and protective relays, as specified by the points list
and comm block diagram, to provide SCADA information to a remote
master station.
vi. Program a local HMI in the RTU to show an animated one line with real-
time values and an alarm annunciator.
vii. Program a remote EMS master using Kepware on Windows.

1.3 Operating Environment

When engineers are designing a new substation that will be built, they must design it so that,
once built, it will remain functional when exposed to regional extreme temperatures and regional
extreme weather. Though the substation designed by the Substation Design team will not be
built, Burns & McDonnell still expects the Substation Design team to design a substation that
would remain functional if exposed to regional extreme temperatures and regional extreme
weather.
1.4 Intended Users and Intended Uses
If the substation designed by the Substation Design team were to be built, the intended use of
the substation would be to raise the voltage of the electric power generated by wind turbines so
that that electric power could be injected into the power grid and distributed to electricity
consumers.

The intended user of the substation would be whichever utility owned it, as that utility would use
the substation to distribute more electric power to its customers. Electricity consumers would
benefit from the operation of the substation, though they would not technically be using it.

1.5 Assumptions and Limitations

Assumptions:
- A new substation in or near Ames, IA is needed
- A 138/69 kV power transformer should be located at the new substation
- The new substation should have a ring bus configuration

Limitations:
- The new substation would be built in or near Ames, IA
- The new substation must be designed such that it complies with relevant client and
industry standards
- The only major pieces of equipment to be located at the new substation are three
138 kV circuit breakers, one 138/69 kV transformer, and one 69 kV circuit breaker
- The new substation should have a ring bus configuration

1.6 Expected End Product and Other Deliverables

The majority of the deliverables for this project will be in the form of documents and drawings
given as a final package to the client. Along with the documents and drawings, our team will
also be providing studies that are the basis for our design package decisions. In addition, our
team will be providing a 3D model of the completed substation, with the major equipment being
displayed in an easy to view manner.
The first deliverable to the client is the grounding and lightning studies. This deliverable shall be
turned over to the client by November 2nd, 2018. The grounding study utilizes software provided
by the client to assist in the design and analysis of the grounding grid. The grounding design will
be reliant on this study and with this study, we will be able to appropriately design a ground grid
that is consistent with IEEE 80 standards and ensures the step and step potential limits and
resistance to remote earth are all within acceptable parameters. The lightning study is an
important piece for designing a substation’s lightning protection in accordance with IEEE
Standard 998-2012. The lightning study will define our calculations used in developing the
layout of the lightning protection, clearly summarize the orientation and protection results for
each grouping of shielding electrodes, summarize the failure rate of the substation, and provide
a recommended configuration of the shielding electrodes which includes the maximum effective
heights of the lightning masts and shield wires.

Our second deliverable to the client is the physical design of the substation, which shall be
turned over by November 30th, 2018. The physical design of the substation will include drawings
which show the layout of the whole substation. The physical design will be shown on a plan
view drawing which will include the locations of the following: the substation equipment, control
building, rigid bus, structures, and the perimeter fence. This deliverable will also include section
cuts from the overall plan view, which will show the elevation view of the substation and also
include the Bill of Material call-outs for major equipment shown in the drawing. This deliverable
will be designed based on the most economical option, which allows for future expansion and
with the client preferences in mind. The grounding and lightning studies will also be taken into
account and the physical design will be shaped by their specifications.

Our third deliverable is the AC/DC studies, which shall be turned over to the client by March 1st,
2019. The AC/DC will specify the size of battery size that will be needed to power the station
during a station service outage. The study will take into account all of the equipment on the site
and will need to follow the standards laid out in IEEE 485. Our study report will need to include a
summary of the design requirements, definitions of the calculations used, and a summary of the
results and our recommendation for the battery design.

Our fourth and final deliverable is the Controls and the Networks, Integration, and Automation
(NIA) design package, which shall be turned over to the client on April 12th, 2019. These
packages will include the final design of the substation’s controls and communications
equipment. The controls package will include several drawings which represent the complete
controls for the substation. These drawings will include a one-line diagram, a 69kV circuit
breaker schematic, a 138kV circuit breaker schematic, a line relay schematic, and the
transformer schematics. Along with these drawings, the package will include the relay panel
layouts for an outside panel vendor to manufacture. The NIA design package will include a
layout for the communications system used at the substation. The package will include: a
communications block diagram and the design of the substation communications equipment
using combinations of serial and Ethernet network equipment, the design of the transport via
fiber to a neighboring substation, quotes for the equipment, an engineering cost estimate, and a
simulation of the network topology using CISCO Packet Tracer.

2 Proposed Approach and Statement of

Work
2.1 Objective of the Task
The objective of our project is to provide our client with design phase services for the new
Cyclone Substation. When completed, the Cyclone Substation will serve as a means of
interconnection between a new wind generation plant being constructed outside of Ames, IA
and the pre-existing transmission system. In order to meet our objectives, our team aims to
design a substation that meets the requirements as specified in the Scope of Services provided
by our client, Burns & McDonnell (BMcD).

2.2 Functional Requirements

Included below is a list of the functional requirements specified in the Scope of Services
provided by BMcD.

Functional Requirement 1 - Specifications

The Cyclone Substation will be prepared with BMcD standard specifications for substation
structural steel, electrical equipment and materials. All required drawings will be generated and
provided by the design team.

Functional Requirement 2 - Site Design

Level ground is assumed during the layout design of the substation. BMcD has provided
designs for the desired site layout by including roadway access to the site, road details and
fencing details.

Functional Requirement 3 - Substation Layout

The Cyclone Substation will be designed with consideration to the most economical option that
provides flexibility towards future expansions. In addition to two (2) or three (3) elevation section
cut drawings, all substation equipment, control building, rigid bus, structures, and perimeter
fence will be generated and indicated on the plan drawings provided by the design team.

Functional Requirement 4 - Bus and Insulator Sizing Design

The design team will perform calculations using predicted fault levels provided by BMcD and
weather criteria to establish the mechanical forces resulting at each of the substation buses.

Functional Requirement 5 - Ground grid

Through hand calculations and the use of software provided by BMcD, the design team will
design the grounding system. The grounding design will be consistent with IEEE 80 techniques,
using a combination of ground mat and rods for arriving at acceptable step and touch potential
limits and resistance to remote earth. Grounding conductors will be sized based on the
calculated fault current value and relay clearing times.

Functional Requirement 6 - Raceway

The design team will design a conduit plan using a combination of surface trenches, subsurface
conduits, and equipment riser conduits.

Functional Requirement 7 - Control Building

The Cyclone Substation will include a control building that accommodates the 125V DC battery
and charger, AC & DC panels, SCADA RTU and all protective relay panels required for the
initial installation. The design team will prepare equipment layout drawings for the substation.

Functional Requirement 8 - 125V DC Station Battery Design

Using IEEE 485 techniques, the design team will develop a battery design for the Cyclone
Substation. Along with considerations of periodic station service outages, loads will be sized,
including future loads, for the sizing of batteries, chargers, and panels used in the 125V DC
system. The design team will develop and submit a report summarizing design requirements,
calculations performed, and results and recommendations for the battery design.

Functional Requirement 9 - Relaying and Controls

The design team will generate a one-line diagram, one 69kV circuit breaker schematic, one
138kV circuit breaker schematic, one line relay schematic, and the transformer schematics.
Relay panel wiring diagrams will be generated by an outside panel vendor as part of the relay
package.

Functional Requirement 10 - Lightning Protection

The Design Team will evaluate and design lightning protection for complete station protection
against direct lightning strikes in accordance with IEEE STD 998-2012 Electro Geometric Model
(EGM) using the empirical curves method. The design team will develop and submit a report
that summarizes calculations used, the orientation and protection results for each grouping(s) of
shielding electrodes, the failure rate of the substation, and a recommended configuration of the
shielding electrodes which includes the maximum effective heights of the lightning masts and
shield wires.

Functional Requirement 11 - Communications

The Cyclone Substation will be completed with a communications system that provides methods
of voice and data transmission among the various system parts in order to maintain satisfactory
operation and control. Communication systems are used in protective relaying schemes to
initiate tripping control schemes of power circuit breakers; in supervisory control systems to
operate remote equipment, for transmission of data indicating equipment status and system
conditions, and for voice communications for system operation and maintenance.

2.3 Constraints Considerations

2.3.1 CONSTRAINTS
This project is constrained by the fact that the Cyclone Substation is not going to be physically
constructed. The objective of this project is to provide engineering design services.
2.3.2 STANDARDS
The Cyclone Substation will be designed in accordance to the BMcD and IEEE standards
relevant to the functional requirements previously specified.

When performing studies and design of the Cyclone Substation grounding system, the IEEE 80
Guide for Safety in AC Substation Grounding will be referenced.

When performing calculations and designing the 125V DC station battery, the IEEE 485
Recommended Practice for Sizing Lead-Acid Batteries for Stationary Applications guide will be
referenced.

When performing studies and design of the Lightning Protection System for the Cyclone
Substation, the IEEE 998 Guide for Direct Lightning Stroke Shielding of Substations will be
referenced.

Throughout this project, the design team will advocate all aspects of the IEEE Code of Ethics as
well as all standards set by our client, BMcD. If our team raises the question of business and/or
engineering ethics at any point during the development of the Cyclone Substation, BMcD will be
contacted.

2.4 Previous Work And Literature

2.4.1 EXISTING TOOLS
Burns and McDonnell has supplied us with several templates, example and to-modify substation
drawings, a detailed Scope of Services, and a start-to-finish Substation Design Guide. Several
aspects of the Cyclone Substation design require the use of IEEE Standard Reference Guides.
The “Design Guide for Rural Substations” that BMcD has supplied to us will prove the most
useful when designing the Cyclone Substation. This guide provides an in-depth treatment in
every aspect of designing a substation.

Due to the fact that BMcD has supplied our team with significant literature regarding substation
design, it is evident that BMcD has developed set standards for completing projects similar to
the new Cyclone Substation. The design team will adhere to these standards set by the client.

2.4.2 RELEVANT LITERATURE

“The 21st century substation design: Vision of the Future” includes discussion on Green Field
Substation design. Because today’s power systems are becoming more and more delocalized,
Green Field substations consider system operation and expansions, the economics of the
power market, and profit optimization. The Cyclone Substation is considered a Green Field
substation. When designing the substation, economics and future expansion into the “Smart
Grid” are being considered. While BMcD has provided us with a concrete plan towards
designing the Cyclone Substation and power economics are outside of the scope of this project,
understanding where the power market is trending will aid us in understanding the big picture of
this project.
REFERENCE: M. Kezunovic, Y. Guan, C. Guo and M. Ghavami, "The 21st century substation
design: Vision of the future," 2010 IREP Symposium Bulk Power System Dynamics and Control
- VIII (IREP), Rio de Janeiro, 2010, pp. 1-8.

2.5 Proposed Design

The design of this substation will be done in accordance with IEEE standards and standards set
by the client. The solution is simple in theory, to design a substation which will serve as an
interconnection for a new wind generation plant being built nearby. However, to design this
substation, data will need to be collected and analyzed. From that data, the substation will need
to be designed with the considerations of the client, IEEE standards, physical obstructions, and
many other factors. Substation design is a defined practice and the solution is straight forward
without much room for alternatives, so these standards and considerations will be our guide to
come up with the deliverables for our client.

2.6 Technology Considerations

Multiple studies are performed throughout the process of designing a substation. These studies
can be done by hand-written calculation, or with the use of computer programs. Our client has
assigned three studies to be performed for this project: a grounding study, a lightning study, and
a DC/AC sizing study. The lightning study and DC/AC sizing study will be done by hand-written
calculation, while the grounding study will be done using a computer program called CDEGS.
The lightning study will be done by hand-written calculation and checked using the program
WinIGS.

2.7 Safety Considerations

There are no foreseen safety concerns with this project.
2.8 Task Approach
Our client provided us a schedule laying out the order of deliverables. The visual below shows a
block diagram of how we will approach the project.

Gather drawings necessary for studies to be performed

Grounding Study Lightning Study

Studies pt.1 Q

Should be working

Three Line / Layout Section Cuts

One Line
Begin working on

Should not prioritize

Q
Physical

AC Study DC Study
Last to be completed.

Studies pt. 2 Q

Controls NIA

P&C

Presentation

Figure 1: Project Approach

2.9 Possible Risks And Risk Management
Our client has provided us with the process to be followed while going through this project. They
also provided instruction for multiple tasks in the project such as studies, drawing examples,
and information on the design process. Because we do not have a budget, there is no material
requirements, and we have detailed instruction guides to reference throughout the time of this
project, there are no foreseen risks.

2.10 Project Proposed Milestones and Evaluation Criteria

The following milestones are proposed as checkpoints for this project:
-Substation Layout Drawing
-Three Line / One Line Drawing
-Studies completion
-Physical Package
-Protection & Control Package

After discussion with our clients, are work will be double checked by the Burns and McDonnell
advisors for accuracy. Each deliverable will be checked by the members of the teams before
passing them off to the Burns and McDonnell advisors.

2.11 Project Tracking Procedures

Our team will use a task tracker created an EXCEL to keep track of the progress of tasks
throughout the project. This tracker includes a task description, due dates, responsible
engineers, and a percentage of completion.

2.12 Expected Results and Validation

The desired outcome of our project is a functionable substation with correct safety standards
and usability. The client, Burns and McDonnell, will confirm our solutions before we submit our
deliverables.

2.13 Test Plan

Because this substation design will not be built, the validation will be based on expert
confirmation from Burns and McDonnell to do an overall quality check of the project.
3 Project Timeline, Estimated Resources,
and Challenges
3.1 Project Timeline
The client has opted to break down this project into four major deliverables: Grounding and
lightning studies, physical design, AC/DC Studies, and Controls & NIA. Within these phases,
there are many subphases that are broken down in section 3.3 Personnel Effort Requirements.
The dates for these deliverables are broken down in the two figures below by semester.

Figure 2: Semester 1 Gantt Chart

Description of Figure 2: Semester 1 Gantt Chart

This semester will begin with an introduction to our project and extensive amounts of research
for the design of the substation. During this phase, we will meet with the client, understand the
scope of work, and create a relationship with our academic advisor. With each member of the
group having various backgrounds on substation design, the introduction and research phase
will ensure that we are all on the same page with similar knowledge. This phase begins on the
first day of school, August 20 and goes to September 23. After the introduction phase, we will
enter the grounding and lightning studies phase. This phase begins on September 24 and the
final deliverables of this phase is due to the client on November 2. This phase deadline is crucial
because we cannot begin the physical design until the grounding and lightning studies are
complete. The physical design phase begins November 3 and the final deliverables of this
phase is November 30.
Figure 3: Semester 2 Gantt Chart

Description of Figure 3: Semester 2 Gantt Chart

During the second semester, we will pick up on the design phase right away. These two phases
will be broken down almost evenly throughout the semester. We will begin with the AC/DC
Studies on January 14. This phase has a little bit of time worked into it to get back into school
and to get a feel for the second senior design class. The final deliverables for this phase are due
March 1. After completion of the AC/DC Studies, we will begin the Controls & NIA phase. This
phase will begin March 2 and the final deliverables will be due on April 12. This semester has
more leeway with finals not being until May 6 to complete any deliverables that we may have
been behind on and to put the finishing touches on the substation design. This also gives us
time to complete any deliverables we may have for the senior design class and ensure we have
time to prepare our presentation.

3.2 Feasibility Assessment

This project design will involve following IEEE Standards, looking at previous drawings, and
using supplementary materials such as the design guide for rural substations that were all given
to us by the client. This project may prove to be difficult because it is such a large-scale
problem. The design guide that was given to us by the client is over 700 pages long and
therefore may be difficult to search through when various problems arise. There is also a huge
learning curve for this project. Some members in our group are familiar with substation design,
whereas others are not at all familiar or very vaguely familiar. This will mean that we will have to
take more time to ensure that we are all on the same page and that we are completing the tasks
accurately and efficiently.

3.3 Personnel Effort Requirements

Table 1- Table 4 below show a list of all the major tasks that need to be done to complete the
project. The tables below are split up by the major deadlines the client has given us: Grounding
and Lightning Studies, Physical Design, AC/DC Studies, and Controls & NIA. This project is
projected to take 400 man-hours. These hours do not consider the introductory research phase
nor the meetings with the clients and our academic advisor.
Grounding and Lightning Studies

Task Description Estimated Time

(hours)

Ground Grid Design and analyze grounding 20

system consistent with IEEE 80 using
CDEGS software.

Lightning Protection Evaluate and design lightning 30

protection for substation in
accordance with IEEE STD 998-2012
using the empirical curves method.

Table 1: Tasks for Grounding and Lightning Studies Phase

Physical Design

Task Description Estimated Time

(hours)

Specifications Create specifications using BMcD 20

standard specifications for substation
structural steel, electrical equipment,
and materials.

Site Design Design roadway access to 10

substation, road details, and fencing
details.
 Substation Layout Layout the substation with the 70
economics and future expansion in
consideration.

Raceway Design conduit plan for substation 30

equipment requiring power or control
connection.

Bus and Insulator Sizing Complete calculations for bus and 15

Design insulator sizes using predicted fault
levels.

Control Building Design the layout of the control 15

building for the substation. This
control building will be sized to fit the
battery system, AC & DC panels,
SCADA RTU and all protective relay
panels.
Table 2: Tasks for Physical Design Phase

AC/DC Studies

Task Description Estimated Time

(hours)

125V DC Station Battery Design a battery system using 20

Design techniques from IEEE 485. This
battery system will be designed with
future loads in mind.

Table 3: Tasks for AC/DC Studies Phase

Controls & NIA

Task Description Estimated Time

(hours)
 Relaying and Controls Generate a one-line diagram, one 75
69kV circuit breaker schematic, one
138kV circuit breaker schematic, one
line relay schematic, and the
transformer schematics.

Communications Create communications block 95

diagram and design the
communication network using both
serial and ethernet network
equipment.

Table 4: Tasks for Controls & NIA Phase

3.4 Other Resource Requirements

As a final physical deliverable for the project, we will be printing the substation layout in 3-
dimensions. This will be done using the Burns & McDonnell 3D printer offered at their
headquarters in Kansas City, Missouri. Burns & McDonnell will supply 3D printing filament
needed to create the 3D substation layout.

3.5 Financial Requirements

For the project, we have few financial resources required. We will be using the software
AutoCAD and CDEGS. AutoCAD has a version available to students for free that should prove
to be adequate for our work, so there will be no cost to our client unless the client’s
specifications change. The software CDEGS will be given to us to use by the client. A license
for CDEGS costs roughly $14,000 and will be shared with other senior design groups across the
country with the same client, Burns & McDonnell. We will also have the expense of 3D printing
our substation design. We will utilize the 3D printer owned by our client, Burns & McDonnell. A
3D printer will usually cost about $1,000, but this cost will not come out of our client’s pocket
because it is already owned. The material for the 3D printer will cost money out of pocket. The
3D printing filament will cost about $19.19 and will be our only cost expense for our client.

4 Closure Materials
4.1 Conclusion
For our senior design project, we have chosen the design of an electrical power substation. An
engineering contracting firm, Burns & McDonnell, has hired our team to develop a 138/69 kV
substation. When completed, our substation will serve as a means of interconnection between a
new wind generation plant being constructed outside of Ames, IA and the pre-existing
transmission system. This substation will raise or lower the voltage of the electric power flowing
into the substation. This will maintain the integrity of the electrical grid by being able to transmit
massive amounts of energy long distances while minimizing power loss within the system.

The approach to this project will follow the scope of services provided to us by Burns &
McDonnell. There are 11 key components of design that we will be breaking up into four
components. They are as follows:

PROJECT TASK DUE DATE

GROUND & LIGHTNING STUDIES 11/02/18

PHYSICAL DESIGN 11/30/18

AC/DC STUDIES 3/01/18

CONTROLS & NIA 4/12/18

We will be following these hard deadlines during the completion of our project. Each project task
listed above has an array of individual components highlighted in our project scope.

Once we have completed the design of our substation, we will be able to perform functionality
tests to prove that our substation will meet all of the required specifications for a power plant.
We will be displaying a 3-D model of our substation along with our designed engineering
drawings.

4.2 References
Advanced Grounding Concepts - Grounding Analysis and Design Software. [Online].

Available: http://www.ap-concepts.com/win_igs.htm. [Accessed: 27-Sep-2018].

“485 - IEEE Draft Recommended Practice for Sizing Lead-Acid Batteries for Stationary

Applications,” IEEE-SA - The IEEE Standards Association - Home. [Online]. Available:

https://standards.ieee.org/project/485.html. [Accessed: 27-Sep-2018].

“80 - Guide for Safety in AC Substation Grounding,” IEEE-SA - The IEEE Standards

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4.3 Appendices
Figures

Gather drawings necessary for studies to be performed

Grounding Study Lightning Study

Studies pt.1 Q

Should be working

Three Line / Layout Section Cuts

One Line
Begin working on

Should not prioritize

Q
Physical

AC Study DC Study
Last to be completed.

Studies pt. 2 Q

Controls NIA

P&C

Presentation

Figure 1: Project Approach

Figure 2: Semester 1 Gantt Chart

Figure 3: Semester 2 Gantt Chart

Tables

Grounding and Lightning Studies

Task Description Estimated Time

(hours)

Ground Grid Design and analyze grounding 20

system consistent with IEEE 80 using
CDEGS software.

Lightning Protection Evaluate and design lightning 30

protection for substation in
accordance with IEEE STD 998-2012
using the empirical curves method.

Table 1: Tasks for Grounding and Lightning Studies Phase

Physical Design

Task Description Estimated Time

(hours)

Specifications Create specifications using BMcD 20

standard specifications for substation
structural steel, electrical equipment,
and materials.

Site Design Design roadway access to 10

substation, road details, and fencing
details.

Substation Layout Layout the substation with the 70

economics and future expansion in
consideration.

Raceway Design conduit plan for substation 30

equipment requiring power or control
connection.
 Bus and Insulator Sizing Complete calculations for bus and 15
Design insulator sizes using predicted fault
levels.

Control Building Design the layout of the control 15

building for the substation. This
control building will be sized to fit the
battery system, AC & DC panels,
SCADA RTU and all protective relay
panels.
Table 2: Tasks for Physical Design Phase

AC/DC Studies

Task Description Estimated Time

(hours)

125V DC Station Battery Design a battery system using 20

Design techniques from IEEE 485. This
battery system will be designed with
future loads in mind.

Table 3: Tasks for AC/DC Studies Phase

Controls & NIA

Task Description Estimated Time

(hours)

Relaying and Controls Generate a one-line diagram, one 75

69kV circuit breaker schematic, one
138kV circuit breaker schematic, one
line relay schematic, and the
transformer schematics.
 Communications Create communications block 95
diagram and design the
communication network using both
serial and ethernet network
equipment.

Table 4: Tasks for Controls & NIA Phase