Power System Design

The design process for a power system can vary enormously depending on the complexity of the power system and the existing site configuration. At one end of the spectrum, we can provide guidance for a simple low voltage DisCo connection, while at the other extreme we can design a tie-in to a complex brownfield site that has limited space and outage windows.

As part of the design approach, iPEC will typically begin by estimating the total power demand, selecting appropriate voltage levels, transformer rating, earthing approach, circuit breaker ratings and fault levels. On more complex sites, we can also then help to establish the required reliability and maintenance requirements of the system, and consider whether to use single radial feeders, ring feeders, or dual radial feeders and different busbar configurations and the need for dynamic UPS or emergency power supplies.

Protection and Control design is a particularly complex area of power systems engineering, and one that carries a high risk if mistakes are made. At iPEC we pride ourselves on our detailed knowledge of protection schemes from simple LV power distribution systems, up to complex transmission systems and large MV motors and generators.

Our approach to protection design is to consider what will be the most appropriate protection scheme for any given item of plant or system and select the most cost-effective scheme based on the amount of capital invested in key equipment and the criticality of the system. As part of the protection design, we would typically consider CT sizing calculations, take decisions on whether the use of differential protection at 33kV and 11kV is justified, and the appropriate selection of some of the more sophisticated types of protection devices required for generators and large motors. Part of this design process also considers the type of control system required, the need for any power management system and the type of communication protocols such as IEC 61850, DNP, MODBUS/TCP, Profibus etc. as well as the system architecture for the control network.

An often-overlooked aspect of power system design is the correct sizing and specification of equipment, and use of appropriate de-rating factors as incorrect sizing can lead to overheating of equipment and loss of useful service life. iPEC has a wide range of established equipment specifications and datasheet templates that can be easily adapted for most Clients’ needs. Preparation of equipment specifications, data sheets and operating philosophies can often seem like an arduous task, but it is vitally important; as allowing manufacturers to provide their standard design, can often lead to contract disputes, and expensive rework.

At iPEC, we regularly undertake sizing calculations for transformers, switchgear and generators and battery sizing calculations for UPS. Our design process ensures that we consider all key aspects of the design requirements, identify and correctly account for any factors that may affect the equipment rating, such as ambient air temperature, altitude, and design life.

Cable Sizing Calculation is an often-misunderstood design process, and it is common to find cables that are not correctly sized, for one reason or another, typically with designers forgetting to consider a cables fault rating, de-rating factors or sheath sizing. At iPEC, we regularly undertake sizing calculations for cables using the different approaches given in BS 7671, IEC 60364, 60502-2 and 60287. We are capable of sizing everything forms LV cables up to complex 330kV transmission cables and their associated Sheath Voltage Limiters (SVLs). Our design process ensures that we consider all key aspects of the cable installation, identify and correctly account for any factors that may affect the cables rating, as well as formally sizing it for the required short circuit carrying capacity.

iPEC has the capability to undertake a wide range of detailed substation designs, from small pad-mounted LV feeder pillars, up to much larger 330kV outdoor substations and complex GIS substation, or hybrid substations. As part of our design, we will typically prepare plan and layout drawings, and associated civil foundation and trench details and during the design, we will consider any arc flash containment ductwork, overhead cranes, battery room configuration and ventilation, shielding
between power and control systems, transformer pen layouts, cable routing and bending radii, Fire & Gas detection, working and operational areas, safety isolation and safety clearances, access for maintainability and also operator access and egress. When considering GIS substation design, we will liaise directly with GIS manufacturers to ensure that the layouts and design reflect the manufacturers
requirements.

iPEC can prepare a wide range of detail design drawings to define the power system design. These documents are necessary to fully define an electrical system and allow a turnkey solution to be provided. Typical drawings that we prepare for clients are: Single line diagrams, protection diagrams, cable routing diagrams, lighting and small power layouts, earthing layouts, hazardous area drawings, wiring diagrams, schematic diagrams, architecture diagrams, block diagrams and many more types!