Civil Design and Construction of 132kv 66kV and 33kV Substation

Guidance Document
Civil Design and Construction

of 132kV, 66kV and 33kV
Substations
Version: 2 Date of Issue: July 2009

Author: Keith Nutter Job Title: Civil Engineer
Approver: Mark Simpson Job Title: Network Standards Manager
Guidance Document
Civil Design and Construction of 132kV, 66kV and 33kV Substations
Revision Log
Version 2 Keith Nutter July 2009
Version 2 DRAFT Keith Nutter May 2009

Draft Update
Version 1 Keith Nutter February 2007
First Issue
Version 0.1 Prepared by Keith Nutter Date November 2006
First Draft
Version: 2 Date of Issue: July 2009 Page 2 of 31

The master version of the this document resides in the E.ON UK Documentum database
CAUTION – any other copy may be out of date
© Central Networks plc
Guidance Document
CONTENTS
1. INTRODUCTION .................................................................................................................. 5
2. SCOPE ................................................................................................................................ 5
3. CHOICE OF SITE .................................................................................................................. 5
3.1 SIZE AND SHAPE ................................................................................................................................................... 5
3.2 GROUND CONDITIONS ........................................................................................................................................ 6
3.2.1 Substrata nature and bearing capacity ...................................................................................................... 6
3.2.2 Ground water levels ............................................................................................................................................ 6
3.2.3 Presence of contaminants ............................................................................................................................... 6
3.2.4 Soil resistivity profile .......................................................................................................................................... 7
3.3 PLANNING CONSENT ........................................................................................................................................... 7
3.4 BUILDING REGULATIONS .................................................................................................................................. 7
3.5 SITE SURVEY ........................................................................................................................................................... 8
3.6 FLOOD RISK ............................................................................................................................................................. 8
4. SITE LAYOUT REQUIREMENTS ........................................................................................... 8
4.1 OPERATIONAL COMPOUND.............................................................................................................................. 9
4.1.1 Plant ........................................................................................................................................................................... 9
4.1.2 Spacing ................................................................................................................................................................... 10
4.2 BUILDINGS ............................................................................................................................................................ 12
4.2.1 Switchrooms......................................................................................................................................................... 13
4.2.2 Control Room ....................................................................................................................................................... 14
4.2.3 W.C. ........................................................................................................................................................................... 15
4.2.4 Store......................................................................................................................................................................... 16
4.2.5 Mess Room 16
4.3 OTHER ...................................................................................................................................................................... 16
4.3.1 Access ...................................................................................................................................................................... 16
4.3.2 Ancillary Plant ...................................................................................................................................................... 17
4.3.3 Services ................................................................................................................................................................... 17
5. DESIGN AND CONSTRUCTION ........................................................................................... 18
5.1 GENERAL ................................................................................................................................................................ 18
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5.2 STANDARDS .......................................................................................................................................................... 19

5.3 BUILDINGS ............................................................................................................................................................ 19
5.3.1 General.................................................................................................................................................................... 19
5.3.2 Walls......................................................................................................................................................................... 20
5.3.3 Floors ....................................................................................................................................................................... 21
5.3.4 Windows and Ventilation ............................................................................................................................... 22
5.3.5 Roofs ........................................................................................................................................................................ 22
5.4 FENCING ................................................................................................................................................................. 23
5.5 TRANSFORMER FOUNDATIONS AND BUND WALLS ............................................................................ 23
5.6 EARTHWORKS/FOUNDATIONS ...................................................................................................................... 23
5.7 CONCRETE .............................................................................................................................................................. 24
5.8 FORMWORK AND REINFORCEMENT .......................................................................................................... 24
5.9 STEELWORK .......................................................................................................................................................... 25
5.10 EQUIPMENT SUPPORT STRUCTURES .......................................................................................................... 25
5.11 CABLE DUCTS / TRENCHES .............................................................................................................................25
5.12 DRAINAGE.............................................................................................................................................................. 26
5.13 SITE SURFACING ................................................................................................................................................. 27
5.14 ROADS AND PATHS ............................................................................................................................................ 28
5.15 NOISE HOUSINGS ............................................................................................................................................... 28
5.15.1 Design ..................................................................................................................................................................... 28
5.15.2 Construction ......................................................................................................................................................... 29
5.16 SECURITY ................................................................................................................................................................ 30
5.17 FIRE PROTECTION ............................................................................................................................................... 30
5.18 DOORS ..................................................................................................................................................................... 31
5.19 HEATING AND LIGHTING ................................................................................................................................. 31
6. APPENDICES
Appendix A: Fire Segregation at Primary and Grid Substations.
Appendix B: Substation Drainage
Appendix C: Transformer Foundations and Bund Walls.
Appendix D: Doors for Primary and Grid Substations
Appendix E: Heating, Lighting and Small Power at Primary and Grid Substations

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1. INTRODUCTION
This document details Central Networks requirements for the design and construction of 132kV,
66kV and 33kV Primary and Grid Substations.
This document must be read in conjunction with the Central Networks Network Design Manual,
Distribution Safety Rules, and other relevant Central Networks Policies and Guidance.
2. SCOPE
This document applies to the design and construction of all Primary and Grid substations at
132kV, 66kV and 33kV that are to be adopted onto the CN Network. It is to be used by Central
Networks staff, Energy Services staff, and External Services Providers.
For substations that are constructed on behalf of customers, and are not adopted as part of the
CN network, then certain amendments relating to future requirements apply. These are noted
within the body of the document.
This document is also to be used where alterations are required to existing Primary and Grid
substations, although it is accepted that it will not be possible to meet all requirements in some
of these cases, due to existing site constraints.
3. CHOICE OF SITE
This section deals with physical factors of the proposed site that can significantly affect its
viability as a substation location. These factors must be considered before construction
commences, and preferably before the land is purchased. In addition to the factors listed below
consideration should also be given at an early stage as to how the Construction phase work will
be undertaken. In particular the requirements of the Construction (Design and Management)
Regulations and the Site Waste Management Plans Regulations should be considered.
3.1 SIZE AND SHAPE
The area of land to be purchased must be of a suitable size and shape to accommodate the
present and future needs as set out in the Site Layout Requirements section. Care must be
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taken to ensure the plot is suitable in all respects and that both existing and potential future
uses of surrounding land have been considered.
In addition suitable access must be available from the public highway. This may require
construction of a simple junction with an existing road, or may require the construction of a
relatively long access road. In either case the access must be suitable for both ’day to day’ use,
and also for delivery of large plant items.
3.2 GROUND CONDITIONS
A Geotechnical Ground Investigation Survey should be carried out to determine the following:-
3.2.1 Substrata nature and bearing capacity
The properties of the existing ground can have a major and costly impact on ground working
and foundations.
Without knowledge of the ground conditions, foundation design and excavation requirements
would have to be based on assumptions. If these assumptions are incorrect, any subsequent
changes required will severely impact on cost and programme.
In some cases where poor ground conditions are encountered, then specialist design and
construction will be required, such as piling and de-watering.
3.2.2 Ground water levels
A high water table might affect foundation design and construction. It may also impact on
ground working methods which again can cause increased costs and programme delays. A
high water table may also impact on cable laying requirements.
3.2.3 Presence of contaminants
Contamination of land can lead to expensive clean up measures or to long term remedial /
monitoring requirements. Contaminants may include:
• Asbestos – Costly specialist removal.
• Heavy metals – All excavated material removed from site will be classed as contaminated
waste, the disposal of which carries a premium price.

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• Oils – Can migrate, via ground water, to adjacent properties and lead to the possibility of
future litigation.
• Gas – either naturally occurring from ground conditions, or from previous uses of the land.
In addition to cost and programme implications, the presence of contaminants may present
potential health risks during both the construction stage and subsequent operation of the site.
It should be noted that if contamination is discovered after the purchase of the land, then
Central Networks will be responsible for clean up costs, unless the original polluter can be
identified.
3.2.4 Soil resistivity profile
This is required to determine if the site is able to support an adequate earthing system.
The resistance of the substation earth will depend on the soil resistivity and the area of the
earth nest. High soil resistivity requires a large site. To determine the earthing requirements
calculations are required in accordance with the Central Networks Earthing Manual.
A ‘Hot’ site in terms of earthing has safety and operational implications – touch, step and
transfer potentials have to be carefully controlled.
3.3 PLANNING CONSENT
If the substation is to be located on an existing operational site, then it is possible that a formal
Planning Consent will not be required. To determine whether a site is exempt, reference should
be made to Schedule 2 (Class G) of The Town & Country Planning (General Permitted
Development) Order 1995.
In all other cases Planning Consent will be required. If the site is located in a sensitive area, i.e.
residential, conservation area, national park, etc, it is preferable to obtain an Outline Planning
Consent before fully committing to purchase of the site.
3.4 BUILDING REGULATIONS
Operational Buildings within substations may be exempt from requiring Building Regulation
approval. They are covered by Building Regulations 2000; Regulation 9; Schedule 2; Exempt
Buildings and Work – Class II; Buildings not frequented by people.

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However there are several other instances, such as connection to existing drainage systems,
which would require a submission under Building Regulations.
It is Central Networks policy that the design and construction of all operational buildings should
comply fully with current Building Regulations, even if approval is not required.
Substations that are designed and build by ESP Contractors and Third Party Developers shall be
subject to full formal Building Regulations Approval, and copies of Consents supplied to Central
Networks to prove compliance with this requirement.
3.5 SITE SURVEY
In order to achieve the most practical and cost effective site layout, a detailed topographic site
survey should be carried out, ideally prior to the purchase of the land.
The site survey information will assist with the design and layout of the site, and will identify
issues with ground levels and suitable access.
3.6 FLOOD RISK
All new Primary and Grid substations should be located and constructed with regard to the
potential flood risk at the site. See the separate policy on flood risk for further guidance.
4. SITE LAYOUT REQUIREMENTS
This section deals with the factors that need to be taken into consideration when designing the
substation layout. The components that make up the layout are generally the Compound (may
be only a transformer compound or may also contain open terminal busbars and equipment),
Building, Access Roads and Fencing. The layout must take into account factors such as
practical use of space available, operational requirements, safety requirements, and inspection
and maintenance requirements.
Before considering possible layouts, the following basic system information is required:-
• Plant and equipment to be accommodated & maintained – type, quantity and
electrical safety clearances.

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• Likely need for future expansion.

• Cables – type, number & site exit/entry locations and directions.
The layout should be prepared using this information, together with the information available
from section 3 above, to give a practical, safe, cost effective solution.
4.1 OPERATIONAL COMPOUND
4.1.1 Plant
At 33kV sites with cable connected transformers there may also be a need for NERs, NER
switches, Fault Thrower cubicles and Ring Main Units.
At 33kV and 66kV sites with open terminal busbars and plant, then the layout may also need to
include for Busbars and supports, Circuit Breakers, Fault Throwers, etc, together with
appropriate ancillary equipment.
At 132kV sites the layout will be dependent on the individual requirements for the substation.
The majority of sites will be open terminal sites with similar plant to the 33/66 open terminal
sites. Some 132kV substations may be constructed as ‘indoor’ sites utilising GIS switchgear.
Where possible, substations at all voltages shall be designed with sufficient space to
incorporate an additional transformer, and switchgear bay where required, at a later date.
(Two transformer sites shall therefore have space for a third unit). 132kV sites may require
additional measures to incorporate future expansion (e.g. space for four transformers with two
installed initially). These requirements will be specified by Network Strategy at the planning
stage.
33kV sites may be designed with 12/24MVA or 20/40MVA transformers. However the
transformer foundations and bunds shall be designed to accept both 12/24 and 20/40 units.
This will allow subsequent upgrading with minimum additional work.
The above requirements may be relaxed where the substation is for a Customers use only and
will not supply distribution load. In these cases the sites can be designed for the exact
requirements of the Customer.

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At 66kV and 132kV sites transformer foundations and bunds shall be designed for the actual
units to be installed, there is no requirement to incorporate any possible upgrading.
4.1.2 Spacing
When designing the compound layout consideration must be given to the following factors:
4.1.2.1 Fire
The clear distance between transformers or between a transformer and any

other oil-containing equipment shall be not less than 12m at 132kV, or 6m at
66kV and 33kV. Where transformers are in noise enclosures this separation may
be reduced but should be not less than 6m at 132kV, or 4m at 66kV and 33kV. If
this separation cannot be achieved then the provision of a fire barrier wall will be
required. This structure shall have a minimum fire resistance of 4 hrs at 132kV, or
2 hrs at 6kV and 33kV.
There shall also be adequate fire separation between the transformers and
control buildings. This shall be not less than 6m.
For full details of fire segregation requirements see Appendix A: Fire Segregation
at Primary and Grid Substations.
4.1.2.2 Touch Potential
In situations where there is more than one earthing system (fence earthed
separated from main earth grid), it is essential that separately earthed plant,
structures, etc are sufficiently spaced so that they cannot be touched
simultaneously. To prevent this, a horizontal separation of 3.0m is preferred, and
a minimum separation of 2.0m must be provided. In certain circumstances
insulated fence panels may be required. Refer to the Earthing Manual for full
details.
4.1.2.3 Access & Maintenance
All plant and equipment shall be provided with sufficient free space to permit
safe operation and maintenance.

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Plant over 2.0m high (which will include all transformers) will require full access
by powered mobile access equipment. Depending on compound layout and
transformer orientation, vehicle access routes within the compound may be
required. Spacing of equipment must be such that access for maintenance is
possible with adjacent plant / circuits live. Refer also to the guidance given in
the Power Systems Operation Manual, section 6.2.
Consideration must be given to means of transformer installation and removal

with the other transformer(s) live. The provision of removable compound fence
panels (i.e., with bolt down posts) will usually be necessary
4.1.2.4 Cable Routing
Cables need to be as accessible as possible, in case of future faults, jointing, etc.

Where cable runs beneath structures cannot be avoided they must be ducted.
It is likely that cable/duct excavation and laying will not occur until after the
structures have been completed. The potential risk of undermining and/or
destabilising the structures must be considered when planning cable routes.
If cable trenches are provided, then the trench and covers must be designed to
support the appropriate applied loading. This may be pedestrian loading only, or
the weight of any plant or vehicles that may need to pass over them for the
purpose of equipment installation and/or maintenance.
4.1.2.5 Fence Layout
In addition to the requirements above for positioning the fence with regard to
touch potential and access and maintenance requirements, the security of the
site must be considered when designing the layout. The compound fence must
be inset from the boundary of the site by a minimum distance of 2 metres. This 2
metre gap prevents neighbours from constructing anything which may be used
as a climbing aid and therefore compromise the security of the site. See section
5.15 for further guidance on site security.

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All compounds must have at least two points of access / egress. On sites with
small cable connected transformer compounds these can be personnel gates, of
minimum width 1.675 metres (centre to centre of gate posts), with removable
fence posts and fence panels provided to cater for transformer removal and
plant maintenance.
On sites of open terminal design, one access / egress must be a set of double
gates of minimum width 4.57 metres (centre to centre of gate posts) to allow
access for maintenance vehicles.
For full details of fencing requirements see separate policy document:

Specification for Fencing for Grid, Primary and Distribution Substations.
4.2 BUILDINGS
All sites will usually require a building to house switchgear, control equipment, etc. The
building shall be segregated from the main compound area. This can be achieved either by
placing the building outside the compound fence area, or by placing the building within the
security fence area, but providing a segregating fence between the building and the compound
plant. Exact layout will depend on site requirements, including an assessment of security
issues.
Buildings will consist of:

Switchroom(s) for the indoor 11kV or 33kV switchgear
Separate control room for relay panels, batteries, LVAC board etc.
Separate store room for cones, chain, etc.
Separate WC
Mess Room – to be provided at certain 132kV substations only (see below)
There is some flexibility in the provision of toilet and mess room facilities, and each proposed
installation shall be subject to a cost/benefit assessment before a decision is made. In some
rural locations the provision of a mains water supply will be uneconomical, and the use of a
suitable ’rainwater harvesting’ may be considered as an alternative.
All rooms must have suitable segregation to meet fire protection requirements. Separate
external access will normally be provided to each individual room; there must be no direct

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connecting doors between rooms. For larger sites the use of a central ‘lobby’ may be utilised
(see below).
On smaller sites the above requirements will usually result in a ‘linear’ building layout with
switchroom, control room and store/WC all in one line. For larger sites, or sites with space
restrictions, other layouts may be preferred.
On larger sites with several rooms the provision of a central lobby may be considered giving
access to control and switch rooms. There MUST still be segregation between rooms with
separate entrances from the lobby area, all fitted with suitable fire doors. If convenient the WC
and mess room (where provided) can also be accessed from the lobby.
On some small sites, such as switching compounds, there may be no requirement for a building,
or the building may be reduced in size. Site specific assessment will be needed to identify
exactly what is required. The provision of a WC shall be carefully assessed for these sites, and
there is also NO requirement for a mess room.
4.2.1 Switchrooms
At 33/11kV substations switchrooms shall usually be designed to accept one of three options for
the 11kV switchgear. Either 13, 17 or 21 panel switchboards will be provided. For certain
projects the Network Planning Section will specify an alternative number of panels. No space
allowance is to be made for future additional units, the number of panels to be installed initially
must take into account future requirements where known. Regardless of initial requirements,
the building must be capable of accommodating 2000 amp switchgear.
There are also some 11kV distribution or consumer sites with requirements for smaller
switchboards, not the ‘standard’ options listed above. The design of these sites is covered in a
separate document.
At 132/11kV, 66/11kV and 132/33kV sites the 11kV and 33kV switchboards are to be designed to
the requirements of the individual site. Again no space should be allowed for future units, but
the number of panels installed initially must take into account known future requirements.
If 33kV and 11kV switchboards are provided at the same site then they must be in separate
rooms.

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All switchboards shall be broken up into discrete ‘sub-boards’ with no more than two
transformer incomers on each. Each ‘sub-board’ shall be housed in a separate switchroom,
segregated by fire barrier walls with no interconnecting doors.
Where modifications are carried out to existing sites, the above design rule for segregation of
switchboards shall be complied with wherever reasonably practicable. For general guidance:
Where additional switchboards with incomer(s) are added to existing sites already having two
or more incomers in one switchroom, the new switchboards shall be segregated by providing
new switchrooms. The new switchroom(s) shall either be separate from existing switch-houses
or fire barrier walls shall be provided between switchboards. Where existing switchboards are
being replaced within existing switch-houses and more than two incomers are involved, then
where it is reasonably practicable to do so, the new switchboard shall be split and fire barrier
walls provided.
There must be sufficient space around plant and equipment for its safe operation, testing and
maintenance, and to allow for future replacement of an individual panel. To accommodate
these requirements the following minimum clearances must be provided:
Rear 1100mm
End 1100mm
Front The greater of: Switchgear panel depth +500mm, OR 2000mm
Head The greater of: IEC test requirements, OR 1000mm
Entrance and exit doors must be sized and positioned to enable pedestrian access, equipment
access, and statutory fire escape requirements. Exact positioning of doors will be dependant on
individual site layout.
For full details of clearances, escape requirements and fire segregation requirements see
Appendix A: Fire Segregation at Primary and Grid Substations.
4.2.2 Control Room
Control rooms shall be designed to accommodate the following equipment as a minimum:
Transformer relay and AVC panels (including space for future units where appropriate)
Telecontrol panel and outstation
Substation battery
Telecontrol battery
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Switchgear local control panel

Feeder and bus section relay panels as required
LVAC board
Intruder alarm panel
Melamine top table, 1200mm by 800mm
2 No canteen style polypropylene stacking chairs
Telephone
Four drawer filing cabinet
Safety notice board
Key cabinet / key safe
Fire point with extinguishers
Door mat – recessed type for ‘computer’ floors, otherwise standard surface mat with non slip
backing
Equipment shall be positioned so there is adequate clearance for installation, inspection,

maintenance and future replacement. Specific minimum distances are required to the front
and rear of control and relay panels, see Appendix A: Fire Segregation at Primary and Grid
Substations for full details.
The height of the control room will usually be the same as the adjacent switchroom, but as a
minimum there must be 500mm clearance above the relay / control panels.
Suitable provision must be made for personnel and equipment access and exit. Usually one
door will be suitable for all requirements but on some larger sites two doors may be required.
The control room access door must be clearly marked as this will be the normal substation
building entry point providing access to the intruder alarm panel.
4.2.3 W.C.
The WC shall contain:
WC suite
Wash hand basin with cold tap and instantaneous electric hot water heater
Separate bib tap for hose connection
Stop tap for incoming water supply
Warm air hand dryer
Toilet roll holder

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Coat hook
Extractor fan with over-run timer connected to lighting circuit
Door mat with non slip backing.
4.2.4 Store
The store room is required for the storage of cones and chain, temporary earths, etc.
On 33kV and 66kV sites a room with a minimum floor area of 3 square metres shall be provided.
On 132kV sites a room with a minimum floor area of 6 square metres shall be provided.
4.2.5 Mess Room
Where mess rooms are provided the nominal size shall be 3.5m by 3.0m. The following items
shall be provided:
Stainless steel single bowl and drainer sink top

Double door cupboard unit to support sink top
Pillar tap for cold water supply
Instantaneous electric hot water heater
Warm air hand dryer
225mm Extractor fan with manual switch
Melamine top table, 1200mm by 800mm
4 No canteen style polypropylene stacking chairs
4 No coat hooks on timber rail
Door mat with non slip backing.
4.3 OTHER
4.3.1 Access
Suitable access must be provided form the public highway to the substation site, and also
within the substation site. All access roads must be suitable for the delivery of large, heavy

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plant items. In addition consideration shall be given for the positioning of a crane to offload
plant items, including transformers.
For 33kV and 66kV sites a minimum road width of 4.0 metres must be provided, and for 132kV
sites this should be a minimum of 4.5 metres. These dimensions are for straight sections of
road; bends will require either a greater road width, or provision for ‘overhang’ of large plant
delivery vehicles. Exact requirements will depend on site layout and access route.
Within the substation site a turning area shall be provided, suitable for a long wheel base panel
van. Where feasible an area for the parking of two cars or vans, which does not block the main
access, should also be provided. This can either be part of the existing road layout or a separate
area of hardstanding.
The design of the junction of the substation access road with the public highway also needs
careful consideration. Designs should take into account sight lines and space required for
turning into / out of the access road.
4.3.2 Ancillary Plant
In addition to the main plant items within the compound there may be a requirement for a
local distribution substation. Where required, allowance shall be made for this within the site
layout, ensuring that access is available for installation of the package switchgear.
4.3.3 Services
In addition to requirements for cabling across the site (power and multicore cables), provision
must also be made for other services. A water supply, surface water drainage (including
interceptor), foul water drainage, and telecoms connection will usually be required.

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5. DESIGN AND CONSTRUCTION
5.1 GENERAL
All aspects of the civil works shall be designed to provide a low maintenance durable end
product suitable for the purpose intended. Particular emphasis shall be placed on security of
the site. Design life for structural elements shall be a minimum of 40 years.
In accordance with the requirements of the Construction (Design & Management)

Regulations the design of buildings and structures should be carried out to ensure that
construction, maintenance and demolition may be carried out in a safe manner.
It is also important that any buildings are built to a high standard and that the finished
building shall be designed to be aesthetically acceptable.
The design of the civil works and the specification of civil materials shall take into account
the environmental impact of all elements. Where possible, ’environmentally friendly’
materials and methods of construction should be incorporated into the works.
E.ON UK has a Biodiversity policy statement which actively supports biodiversity across the
business. Central Networks supports this policy on Primary and Grid substations by
integrating biodiversity considerations into the design process. Planners and Designers
should make provision for these where appropriate. See the Central Networks Environment
Manual for further information.
Emphasis is placed upon prevention and limitation of fire damage. Measures are specified
in Appendix A: Fire Segregation at Primary and Grid Substations, and these shall be adopted
as a minimum requirement. This document shall also be used as a guide for clearances
around switchgear and other equipment. Power cables and control cables shall be routed
and/or segregated such that minimal loss of control or supplies occurs in the event of fire or
damage.
With modern SF6 and vacuum switchgear there is no requirement to incorporate any blast
relief measures into the building construction. Where existing oil filled switchgear is used
in a building requiring alteration or extension then consideration shall be given for the need
for blast relief measures.

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5.2 STANDARDS
All design and construction including all materials, testing and other procedures shall be
undertaken in accordance with appropriate Electricity Supply Industry Standards and
current British / European Standards.
5.3 BUILDINGS
5.3.1 General
Buildings may be either:
• Brick / block construction with a variety of different roof constructions.
• Steel portal frame design with profile steel sheet cladding, and brick / block perimeter
walls to a minimum height of 2.0 metres.
• Other proprietary design, such as a panel system, subject to the approval of Network
Standards.
Access to plant and apparatus shall be adequate for operational and maintenance purposes
and provision shall be made for escape in the event of fire. The escape route shall be
designed to be clear of any obstructions. Passageways and the minimum spacing between
equipment shall be provided in accordance with Appendix A: Fire Segregation at Primary
and Grid Substations.
Provision shall be made for entry of power, multicore, telephone and pilot cables, water
supply and foul drainage pipes.
Sufficient width and depth shall be available for the cable routes such that de-rating of the
11kV feeder cables is kept to a minimum. There shall be no mutual de-rating of outgoing
feeder, Bus Interconnector or Transformer Incoming 11kV cables.
Ducts from buildings shall normally extend a minimum distance of 500mm from the
external face of the building. If the access road is immediately adjacent to the building,
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then the ducts should be continued beneath the access road to facilitate cable installation.
5.3.2 Walls
All brickwork and blockwork shall be of a high standard facing quality with bucket handle
pointed joints externally and flush pointing internally, unless a match with existing
brickwork pointing is required. Where possible all dimensions shall be in modular sizes to
minimise cutting of bricks and blocks.
Clay facing bricks 65mm thick shall be used externally and shall be a minimum strength of
50N/mm2 and a maximum water absorption of 7% when tested in accordance with the
appropriate British Standard. All facing bricks used externally shall be F2 frost resistant
designation.
Internal walls shall be constructed to give a durable, low maintenance, dust free finish.
Walls shall be painted with smooth masonry paint, magnolia colour. The final coat of paint
is to be applied after installation of electrical equipment.
All proposed bricks and blocks to be used are to be approved by the Company’s
representative. Aerated concrete blocks are not acceptable for internal or external walls.
Quoin blocks shall be used at cavity closures in blockwork.
Cavity walls in substation buildings shall achieve a U value as required by the current issue of
the Building Regulations for new buildings other than dwellings.
All brickwork and blockwork shall be laid in mortar of appropriate strength for the location
and exposure of the wall.
Facing brickwork shall be used in the outer leaf below DPC level and shall extend at least 2
courses below finished ground level on all faces of the building. The type and colour of
facing bricks used shall comply with Local Authority requirements. Bricks for use below
ground shall be approved Class B uniform colour engineering bricks
Wall ties shall be stainless steel. Solid walls of one brick thickness or greater to be cross
bonded or tied together with stainless steel reinforcement or ties.
Where expansion or contraction joints are incorporated they shall be constructed with

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approved joint filler and finished with appropriate coloured sealant. Expansion joints shall
be so positioned as to coincide with Brick/Block modular sizes to avoid unnecessary cutting.
5.3.3 Floors
Floors of switch-houses will be of reinforced concrete power float finish and designed to
withstand the weight of switchgear to be installed. The finished floor level will normally be
a minimum of 150mm higher than the substation compound. Solid concrete floors shall
incorporate a damp proof membrane.
Floors shall be sealed against dust prior to installation of plant, and finished with light grey
coloured floor paint. The final coat of paint is to be completed after installation of electrical
equipment.
Unistrut channels are to be set into the switchroom floor to provide fixings for the
switchgear.
Floors of control rooms may be of reinforced concrete, or removable floor panels supported
on pedestals on a concrete sub-floor. Floor panels are to have an antistatic sheet vinyl
finish. A suitable skirting shall be provided around the room perimeter. Concrete floors are
to be finished as stated above.
Where internal cable trenches are provided they shall be fitted with GRP or recycled plastic
removable covers (with suitable lifting holes) on galvanised steel bearers or concrete walls.
Covers shall have a non slip solid top surface. Covers shall be designed for easy removal
and reinstatement, and shall be of manageable dimensions and weight. Trench designs
shall incorporate suitable access arrangements including ladders, step irons and hand rails
where appropriate.
Where water ingress is considered possible, cable trenches within buildings shall be fitted
with drainage gullies connected to the storm drainage system, or with a sump and
automatic pump.
All ducts passing into buildings shall be sealed to prevent ingress of water and vermin.
Minimum depths of external ducts shall generally be 450mm for multicore cables and
750mm for power cables.

Guidance Document
There is no requirement to comply with the U value for floor elements, as stated in the
Building Regulations, but floors shall be designed to be as ‘energy efficient’ as possible
whilst accommodating the various cable entries required.
5.3.4 Windows and Ventilation
Windows are not required for daylight conditions or ventilation in substation and shall not
therefore be provided. Adequate mechanical ventilation shall be provided to the W.C. and
Mess Room as required by Building Regulations. No natural or forced ventilation is required
to other rooms.
5.3.5 Roofs
Roofs can be a variety of different constructions including:
• Flat and constructed from pre-cast concrete beams overlaid with insulation board and/or
lightweight screed laid to falls and covered with asphalt, or built up felt system.
• Flat, with steel supporting structure and metal profile sheeting, finished with insulation and
built up felt system.
• Pitched, with concrete or clay tile finish on timber trusses or rafters. Ridge and edge
details shall be of low maintenance proprietary design. Consideration shall be given to
security aspects of pitched roofs, and these shall normally be used where the building is
within the security boundary of the site.
• Portal frame construction with steel profile sheet cladding.
• System roof made up from proprietary system panels
Single ply membrane systems will not be accepted.
For some of the above roof options a parapet or edge upstand will be required. Parapets
should be of suitable structural design and may be 3 or 4 sided with a gutter or roof outlets
as required. The roof design shall ensure efficient removal of rainwater and not create
areas of ponding. The roof covering should be turned up the inside of the parapet/upstand
and across the top to terminate in a suitable GRP trim. Coping stones will not be accepted.
Guidance Document
Care must be taken to ensure that rainwater does not stand on top of the parapet and then
run down the face of the brickwork through the joints in the GRP trim.
Where fascia and soffit boards are provided, these shall be of low maintenance design (e.g.
uPVC).
The overall construction of the roof shall be such as to provide a minimum thermal insulation U
value as required by the current issue of the Building Regulations for new buildings other than
dwellings. Solar heat gain shall be limited by the use of suitable solar reflective finishes.
Adequate means for the disposal of rainwater from the roof shall be made. Where possible,
connections shall be made to the main surface water drain.
The underside of pre-cast concrete roof units shall have a fair face finish. Units shall be
manufactured with tolerances specified in the appropriate British Standard. Differences in
soffit level of two adjacent units shall not exceed 6mm.
The underside of pre-cast concrete roof units, or any other separate ceiling construction,
shall be painted with matt white emulsion paint.
Roofs shall be designed for occasional access and maintenance, snow and wind loading in
accordance with the appropriate British Standard.
5.4 FENCING
For full details of the fencing requirements see separate policy document: Specification for
Fencing for Grid, Primary and Distribution Substations.
5.5 TRANSFORMER FOUNDATIONS AND BUND WALLS
For full details of the design and construction of transformer foundations and bund walls
see Appendix C: Transformer Foundations and Bund Walls.
5.6 EARTHWORKS/FOUNDATIONS
Any earthworks shall be carried out in accordance with the Manual of Contract Documents
for Highways Work: Volumes 1 and 2, as published by the Highways Agency. General site fill
Guidance Document
material shall be imported graded granular material to the approval of the Company’s
representative. All surplus spoil will be removed from site. An assessment of any imported
fill material must be made to ensure it is compatible with the earthing requirements of the
site.
Suitable measures to mitigate unsuitable or contaminated ground conditions shall be

adopted by the contractor. Measures may include removal or in situ treatment of the
ground or containment. All such works shall be conducted in accordance with procedures
approved by the relevant environmental authorities. Foundations and other below ground
constructions shall be designed to resist chemical attack from ground contaminants.
Excavations for foundations shall be taken down to such depths as to provide a solid
foundation suitable for the loading to be applied. Foundations shall be taken down to
sufficient depth to avoid being undermined by cable trench excavations. Foundations shall
be of a type to suit the ground conditions and shall be designed such that long term
differential settlement is kept within acceptable limits for operation of the electrical plant
and apparatus.
The total area of the substation compound must be suitable for access by a mobile elevated
work platform. (MEWP) The existing subgrade must be assessed for MEWP access. A layer
of suitable graded stone (MOT type 1 or 2) will be provided beneath the substation
surfacing. The thickness of the stone layer will be designed to support the MEWP, but must
be a minimum of 100mm. The Contractor will be responsible for any additional subgrade
improvement that is required solely for construction use.
5.7 CONCRETE
All structural concrete for work below ground level shall meet the requirements for
sulphates as identified for each particular site. In addition suitable measures must be taken
to avoid the risk of alkali-silica reaction.
The minimum grade of structural concrete shall have a cube crushing strength of 35 N/mm2
at 28 days.
5.8 FORMWORK AND REINFORCEMENT
All concrete surfaces except top surfaces shall be constructed using suitable formwork of a
Guidance Document
quality and strength necessary to obtain true surfaces with a fair face.
Where concrete is exposed at or above ground level, formed and unformed surfaces shall
have the following grades of finish:
All exposed items Type F3 finish
Unseen surfaces Type F1 finish
Top unformed surfaces Type U3, steel trowel finish
All finishes are as specified in the Manual of Contract Documents for Highways Work:
Volume 1, as published by the Highways Agency.
Bases for steel or aluminium structures, transformers and other kiosks shall be set 75mm
above finished compound level, and their edges finished with chamfers. Edges of bases and
trenches cast flush with the compound level shall be finished with a bull-nosed trowel.
Formwork ties will not be permitted to pass through oil bund walls or exposed structural
concrete.
5.9 STEELWORK
Any structural steelwork incorporated into the works shall receive appropriate surface
preparation and be hot dip galvanised in accordance with BS EN ISO 1461. Likewise all
associated fasteners, packings, etc. shall receive the same galvanised treatment.
5.10 EQUIPMENT SUPPORT STRUCTURES
Support structure for plant and equipment including busbars shall be constructed from
galvanised steel or aluminium. Structures shall be designed to accommodate all normal
vertical and horizontal loads plus additional loadings associated with electrical fault
conditions.
5.11 CABLE DUCTS / TRENCHES
All cable ducts and trenches shall be designed to cater for specified future requirements
and shall be of suitable construction to sustain all stated applied loadings.
The preferred option is to direct lay all power and multicore cables with suitable ducts
Guidance Document
beneath roads and other inaccessible areas. Ducts for power and multicore cables will
generally be 125mm diameter and coloured black. On larger sites a cable duct and pit
system may be used for multiicore cables. Alternatively an in situ or precast concrete
trough solution is acceptable. Minimum depths of external ducts shall generally be 450mm
for multicore cables and 750mm for power cables.
When laying cable ducts the opportunity should be taken to lay additional spare ducts for
potential future use. This is particularly advantageous beneath access roads or foundations.
Covers of cable trenches/pits shall be so designed to carry the applied loadings and to be
capable of being removed easily without a risk of compound chippings falling into the
trench/trough. Also, when in place, lids shall not present a trip hazard.
The preferred trench cover material is either GRP with a solid top surface or Recycled Plastic
covers. In certain circumstances heavy duty trench covers may be necessary.
(See separate specification document for details of trench covers).
Trenches into buildings and compounds shall be designed so they cannot be used to gain
unauthorised access into these areas. This may require the use of lockable covers.
Bases of cable trenches shall be laid to falls and include suitable drainage provision. Where
possible the drainage points shall be connected to the site surface water drainage system.
5.12 DRAINAGE
For drainage requirements on Primary and Grid substation sites see Appendix B: Substation
Drainage
For drainage requirements associated with transformer bund walls see Appendix C:
Transformer Foundations and Bund Walls
Suitable waste pipes and drainage gullies shall be provided to take away the condensate
from dehumidification equipment.
Surface water and foul drainage systems shall comply with the requirements of the
appropriate statutory authorities. Discharge into water courses or into the any existing
drainage systems will not be permitted without written consent of the appropriate

Guidance Document
statutory authorities, which shall be obtained prior to commencement of the works.
The design of the drainage systems must take into account the loadings which may be
applied from heavy vehicles such as transformer delivery vehicles, or the use of MEWPs in
compound areas.
5.13 SITE SURFACING
All newly developed or re-developed areas of substation compound shall be stripped of all
topsoil and vegetation.
The finished area of the substation compound shall be resurfaced with a low maintenance
finish suitable for easy access for maintenance of equipment. This layer will also act as an
electrical insulator to minimise touch and step potentials during electrical fault conditions.
This finish will be a 75mm thickness of 20mm single size granite, basalt or carboniferous
limestone chippings laid on geotextile material conforming to clause 609 of the Specification
for Highway Works (SHW), Volume 1 of the Highways Agency’s Manual of Contract Documents
for Highway Works. Other similar types of chippings may be suitable subject to approval by the
Company.
The chipping layer must extend a minimum of 1.5 metres outside the line of the compound
fence.
Site surfacing and geotextile material shall not be laid until after installation of all cables
and electrical equipment. It is the Contractor’s responsibility to protect the formation prior
to laying of the geotextile material and surfacing
Areas outside the compound but within the boundary fence shall generally be finished in
accordance with the compound requirements above. However on some sites there may be
a planning requirement for landscaping which will replace some of the stone chipped areas.
All landscaping shall be designed to avoid future problems with overhead lines, buried
services, etc. and must have minimum maintenance requirements.

Guidance Document
5.14 ROADS AND PATHS
Site roads which may be used for the moving of heavy items of plant should normally be
designed to cater for transformer delivery vehicles. It is essential to ensure that all cable
ducts and other services which are to be laid under substation roads are in position before
construction of the road commences.
Roads shall be designed to suitable horizontal and vertical alignments to meet the
requirements in the Site Layout section above. In particular vertical alignments shall avoid
sharp gradient transitions. Within compounds gradients shall kept to a minimum and will
usually be determined by drainage requirements. Roads shall generally have upstand kerbs
to direct water flows, and to contain any oil spillage within the drainage system
The roads shall preferably be of dense bitumen macadam or hot rolled asphalt construction.
Thickness of base and wearing course materials shall be calculated from design loads but
shall be a minimum of 60mm and 30mm respectively.
For substation buildings suitable concrete access paths shall be provided for access to
normal entry doors and doors designated for delivery of plant. Other doors should have a
simple concrete pad outside the door. All paths and pads shall have a non slip finish and
should direct any rainwater away from the building.
5.15 NOISE HOUSINGS
5.15.1 Design
Noise housings shall be constructed from proprietary ‘sandwich’ panels consisting of an

inner and outer metal sheet with sound absorbing filler material. The proposed design shall
have appropriate fire resistance as stated in Appendix A: Fire Segregation at Primary and
Grid Substations and shall be approved by the Company’s representative prior to
fabrication.
The required insertion loss to be provided by each enclosure shall be agreed between the
Company and the manufacturer following the necessary site noise survey.
The enclosures shall be designed and constructed as to allow sufficient room for access for
maintenance on the transformer and its ancillaries. Where power or multicore cable runs
Guidance Document
restrict pedestrian routes inside housings, suitable galvanised steel internal walkways and
steps shall be designed and fitted to provide safe access.
The enclosure shall be designed to withstand all superimposed and wind loads, including
maintenance access loading for the roof construction.
Provision shall be made for the collection of rainwater and its disposal into the bunded area.
A suitable foam inlet for fire fighting purposes shall be provided to the housing.
Vermin proof grilles shall be provided to apertures between housing and cooler areas.
The position of enclosure walls shall be determined using the minimum requirements in
Appendix A: ‘Fire Segregation at Primary and Grid Substations, and in Appendix C:
Transformer Foundations and Bund Walls.
Two steel lockable access doors shall be provided with each enclosure at diametrically opposite
corners with appropriate fire resistance to match that of the housing (generally 2 or 4 hours).
The doors shall give a clear opening 2000mm high by 750mm wide. Doors shall close on to
resilient seals along all meeting faces.
Doors shall be fitted with:

• Push bar panic latch with external LEVER type lockable handle incorporating europrofile
cylinder
• Garage type hold open stay
• Emergency exit signage as appropriate.
Concrete or steel steps shall be provided to allow safe access/egress to the housing over the
bund wall. Externally a minimum 900mm square platform shall be provided with steps and
handrails.
5.15.2 Construction
For the protection of transformer paintwork, it is a requirement that enclosure roofs shall be
waterproofed and that all seals around pipe work and turrets are water tight.
Proprietary metal sandwich panel construction housings shall have panels bolted together

Guidance Document
using a suitable resilient gasket materials to form a watertight seal.
All components shall be galvanised after fabrication. In some instances a coloured paint finish
may be required on top of the galvanising to meet planning requirements. No site drilling or
welding of the housing components will be permitted.
5.16 SECURITY
All sites shall be risk assessed to determine what security measures are appropriate. The
minimum requirement for all sites is to have an intruder alarm which covers the building and
the compound access gates. The risk assessment will determine what type of boundary fencing
is appropriate, subject to planning agreement, and also if further measures such as electric
fences to compounds or close circuit television systems are required. Specifications for intruder
alarms and CCTV systems are provided by the E.ON UK Security Technical Installations Manager.
Substation buildings shall be located, where possible, so they are either inside or outside a
security palisade fence, depending on security risk assessment.
If due to lack of space a substation building forms part of a security perimeter of a site, then
additional measures should be considered to ensure adequate protection. In particular walls
shall be ‘smooth faced’ without climbing aids, and rainwater pipes shall be positioned inside
the security perimeter, or protected by anti climb measures to prevent unauthorised access.
Measures must also be taken to prevent theft of earth tape. Any exposed earth tape must be
capped in accordance with the requirements stated in the Earthing Manual.
5.17 FIRE PROTECTION
Sites must be individually fire risk assessed to determine what fire prevention and fire
fighting measures are appropriate.
For relatively simple layout sites with single storey buildings then the following minimum
requirements will usually be adequate:

Guidance Document
• All buildings shall be fitted with smoke detectors to switchrooms and control rooms.
• All buildings shall be fitted with a minimum of one fire fighting point, usually situated
immediately inside the control room door. The fire point will consist of one dry powder
extinguisher and one carbon dioxide extinguisher, together with appropriate labels.
Central Networks will supply and install the fire extinguishers.
• A fire action notice will be provided adjacent to the telephone point.
• All fire exit routes and final exit doors will be marked with appropriate standard fire exit
signage.
For more complex sites additional fire prevention and fire fighting equipment may be
required, dependant on the fire risk assessment.
For further details see the separate policy document: Fire and Bomb Safety at Operational Sites.
5.18 DOORS
For full details see Appendix D: Doors for Primary and Grid Substations
5.19 HEATING AND LIGHTING
Design and installation of heating and lighting systems, including LV power systems, is detailed
in Appendix E: Heating, Lighting and Small Power at Primary and Grid Substations. This
document also includes information on floodlighting for substations, intruder alarms and other
associated electrical items.


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Civil Design and Construction of 132kv 66kV and 33kV Substation

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Guidance Document

Civil Design and Construction

Version: 2 Date of Issue: July 2009

Version 2 DRAFT Keith Nutter May 2009

Version: 2 Date of Issue: July 2009 Page 2 of 31

5.2 STANDARDS .......................................................................................................................................................... 19

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3.1 SIZE AND SHAPE

3.2 GROUND CONDITIONS

3.2.1 Substrata nature and bearing capacity

3.2.2 Ground water levels

3.2.3 Presence of contaminants

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3.2.4 Soil resistivity profile

3.3 PLANNING CONSENT

3.4 BUILDING REGULATIONS

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3.5 SITE SURVEY

3.6 FLOOD RISK

4. SITE LAYOUT REQUIREMENTS

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• Likely need for future expansion.

4.1 OPERATIONAL COMPOUND

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The clear distance between transformers or between a transformer and any

4.1.2.2 Touch Potential

4.1.2.3 Access & Maintenance

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Consideration must be given to means of transformer installation and removal

4.1.2.4 Cable Routing

Cables need to be as accessible as possible, in case of future faults, jointing, etc.

4.1.2.5 Fence Layout

Version: 2 Date of Issue: July 2009 Page 11 of 31

For full details of fencing requirements see separate policy document:

Buildings will consist of:

Version: 2 Date of Issue: July 2009 Page 12 of 31

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4.2.2 Control Room

Control rooms shall be designed to accommodate the following equipment as a minimum:

Switchgear local control panel

Equipment shall be positioned so there is adequate clearance for installation, inspection,

The WC shall contain:

Version: 2 Date of Issue: July 2009 Page 15 of 31

4.2.5 Mess Room

Stainless steel single bowl and drainer sink top

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4.3.2 Ancillary Plant

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5. DESIGN AND CONSTRUCTION

In accordance with the requirements of the Construction (Design & Management)

Version: 2 Date of Issue: July 2009 Page 18 of 31

Buildings may be either:

• Brick / block construction with a variety of different roof constructions.

Version: 2 Date of Issue: July 2009 Page 20 of 31

Version: 2 Date of Issue: July 2009 Page 21 of 31

5.3.4 Windows and Ventilation

Roofs can be a variety of different constructions including:

• Portal frame construction with steel profile sheet cladding.

• System roof made up from proprietary system panels

Single ply membrane systems will not be accepted.

5.5 TRANSFORMER FOUNDATIONS AND BUND WALLS

Suitable measures to mitigate unsuitable or contaminated ground conditions shall be

5.8 FORMWORK AND REINFORCEMENT