Substation Design & Operation: 5-Day Professional Training Course

Course Overview

This comprehensive Substation Design and Operation Training provides essential knowledge of power substation engineering, equipment specification, protection systems, and operational practices. This intensive 5-day program covers substation types, layout design, equipment selection, protection and control schemes, testing procedures, operational safety, and maintenance strategies for transmission and distribution substations in utilities, industrial facilities, and renewable energy projects.

Who Should Attend This Substation Engineering Course?

• Substation Design Engineers in utilities and consulting firms

• Protection and Control Engineers designing relay schemes

• Substation Operations Personnel and supervisors

• Project Engineers managing substation construction

• Electrical Engineers in transmission and distribution

• Maintenance Engineers responsible for substation equipment

• Planning Engineers conducting system expansion studies

• Commissioning Engineers for substation projects

• Power System Engineers in generation and utilities

• Safety Officers overseeing substation operations

Course Objectives

Participants will master:

• Substation design principles and configuration options

• Equipment specification: transformers, circuit breakers, switchgear

• Bus arrangement layouts and selection criteria

• Protection and control system design

• Substation automation and SCADA integration

• Testing, commissioning, and energization procedures

• Operational safety practices and switching procedures

• Maintenance strategies for substation reliability

Day 1: Substation Fundamentals and Design Principles

Morning Session: Introduction to Substations

Topics Covered:

• Power substation definition and functions in power systems

• Substation classifications: transmission, distribution, switching, collector

• Voltage levels: EHV, HV, MV, LV applications

• Substation types: outdoor (AIS), indoor, Gas-Insulated Substation (GIS)

• Mobile and containerized substations

• Single-line diagram representation and conventions

• Power flow and voltage transformation fundamentals

• Substation role in grid reliability and stability

Key Concepts:
Understanding how substations connect generation, transmission, and distribution systems.

Afternoon Session: Substation Configuration and Layout

Topics Covered:

• Bus arrangement types and configurations

• Single bus arrangement: advantages and limitations

• Main and transfer bus configuration

• Double bus double breaker arrangement

• Breaker-and-a-half scheme

• Ring bus configuration

• 1½ breaker arrangement

• Layout selection criteria: reliability, cost, flexibility, maintenance

Design Considerations:

• Reliability indices and N-1 contingency analysis

• Expansion capability and future-proofing

• Land requirements and site constraints

• Lightning protection zones and clearances

• Minimum electrical clearances per voltage level

Workshop:
Comparing bus arrangements for different applications and reliability requirements.

Day 2: Substation Equipment and Specifications

Morning Session: Power Transformers

Topics Covered:

• Power transformer fundamentals: construction and operation

• Two-winding and three-winding transformers

• Transformer ratings: MVA, voltage class, impedance

• Cooling methods: ONAN, ONAF, OFAF, OFWF

• Tap changers: on-load (OLTC) and off-load types

• Vector groups and phase displacement

• Transformer connections: star, delta, zigzag

• Transformer protection: Buchholz relay, PRD, temperature monitoring

Transformer Selection:

• Load analysis and sizing calculations

• Impedance selection for short circuit limitation

• Loss evaluation and efficiency considerations

• Environmental and noise requirements

Afternoon Session: Circuit Breakers and Switchgear

Topics Covered:

• Circuit breaker technologies: vacuum, SF6, air blast, oil

• Circuit breaker ratings: voltage, current, breaking capacity

• Operating mechanisms: spring, hydraulic, pneumatic

• Interrupting time and operating sequence

• Medium voltage switchgear: metal-clad, metal-enclosed

• High voltage switchgear configurations

• Circuit breaker selection criteria

• Standards: IEC 62271, IEEE C37 series

Switching Devices:

• Disconnectors (isolators) and earthing switches

• Load break switches and fault make switches

• Circuit switchers for moderate duty applications

• Surge arresters: metal oxide varistor (MOV) technology

Equipment Workshop:
Specifying circuit breakers and switchgear for various substation applications.

Day 3: Protection Systems and Control Architecture

Morning Session: Substation Protection Principles

Topics Covered:

• Protection system philosophy and zones of protection

• Primary and backup protection coordination

• Transformer protection: differential, overcurrent, REF

• Feeder protection: overcurrent, distance, directional

• Bus protection: differential and high impedance schemes

• Circuit breaker failure protection

• Voltage and frequency protection

• Earth fault protection schemes

Relay Technology:

• Electromechanical vs. numerical relays

• Microprocessor-based multifunction relays

• Relay setting calculations and coordination

• Protection communication: pilot wire, fiber optic, power line carrier

Afternoon Session: Substation Control and Automation

Topics Covered:

• Substation automation systems (SAS) architecture

• SCADA (Supervisory Control and Data Acquisition) integration

• Remote Terminal Units (RTU) and Intelligent Electronic Devices (IED)

• IEC 61850 communication protocol

• Station bus and process bus concepts

• Bay control units and protection relays

• Human-Machine Interface (HMI) design

• Event recording and disturbance analysis

Control Systems:

• Local control panels and switchgear control

• Remote control from control centers

• Automatic vs. manual control modes

• Interlocking and permissive logic

• Sequence of events (SOE) recording

Case Study:
Modern substation automation design with IEC 61850 communication.

Day 4: Auxiliary Systems and Physical Design

Morning Session: Auxiliary Power and Services

Topics Covered:

• Station auxiliary power systems: AC and DC

• Battery systems: lead-acid, VRLA, lithium-ion

• Battery chargers and DC distribution

• UPS systems for critical loads

• Auxiliary transformers and distribution

• Lighting systems: normal and emergency

• HVAC systems for control buildings and equipment shelters

• Fire detection and suppression systems

Grounding and Lightning Protection:

• Substation grounding grid design

• Step and touch potential calculations

• Ground grid resistance and soil treatment

• Lightning protection systems for substations

• Shielding angle method and rolling sphere method

• Overhead ground wires (OHGW)

• Surge arrester coordination

Afternoon Session: Physical Layout and Civil Works

Topics Covered:

• Substation site selection criteria

• Plot plan development and equipment arrangement

• Access roads and vehicle circulation

• Cable trenches and conduit systems

• Foundation design for equipment

• Control building layout and equipment rooms

• Fencing, gates, and security systems

• Drainage and site grading requirements

Environmental Considerations:

• Noise control and mitigation

• Oil containment systems for transformers

• Environmental regulations and compliance

• Visual impact and landscaping

• Wildlife protection measures

Design Exercise:
Developing a complete substation plot plan with equipment placement.

Day 5: Testing, Commissioning, and Operations

Morning Session: Testing and Commissioning

Topics Covered:

• Pre-commissioning inspection procedures

• Factory Acceptance Tests (FAT) requirements

• Site Acceptance Tests (SAT) procedures

• Primary equipment testing: transformers, circuit breakers

• Secondary equipment testing: protection relays, control circuits

• High voltage testing: withstand and induced voltage tests

• Insulation resistance and power factor testing

• Functional testing and integrated system tests

Commissioning Standards:

• IEC 61850 conformance testing

• Protection relay commissioning procedures

• SCADA and communication system testing

• Energization procedures and checklists

Afternoon Session: Substation Operations

Topics Covered:

• Switching operations and procedures

• Operating orders and clearance permits

• Normal switching sequences

• Emergency switching procedures

• Isolation and earthing protocols

• Safety rules and precautions

• Personal protective equipment (PPE) requirements

• Arc flash hazard and boundary calculations

Operational Safety:

• Live working vs. dead working procedures

• Lockout/tagout (LOTO) implementation

• Approach distances and safe working zones

• Emergency response procedures

• Accident investigation and reporting

Maintenance and Asset Management

Topics Covered:

• Preventive maintenance programs for substations

• Transformer oil testing and analysis

• Circuit breaker maintenance and testing

• Battery maintenance and capacity testing

• Protection relay testing schedules

• Condition monitoring techniques: thermography, partial discharge

• Asset health indexing and risk assessment

• Maintenance planning and outage scheduling

Predictive Maintenance:

• Dissolved Gas Analysis (DGA) for transformers

• SF6 gas monitoring and handling

• Acoustic and ultrasonic testing

• Vibration analysis for mechanical equipment

Advanced Topics and Special Applications

Gas-Insulated Substations (GIS):

• GIS technology advantages and applications

• Single-phase vs. three-phase GIS

• GIS commissioning and testing

• Partial discharge testing in GIS

• SF6 gas handling and environmental considerations

• Space requirements comparison: GIS vs. AIS

Mobile and Modular Substations:

• Mobile substation applications

• Emergency restoration substations

• Containerized substation designs

• Rapid deployment strategies

Renewable Energy Substations:

• Solar farm collector substations design

• Wind farm substations and offshore applications

• BESS (Battery Energy Storage System) integration

• Inverter-based generation protection challenges

• Grid code compliance requirements

HVDC Converter Stations:

• HVDC technology overview

• Converter station equipment and layout

• AC/DC conversion principles

• HVDC protection and control systems

Standards and Regulations

International Standards:

• IEC 61936: Power installations exceeding 1 kV AC

• IEC 62271: High-voltage switchgear and control gear

• IEC 60076: Power transformers

• IEC 61850: Communication networks for substations

• IEEE C37 series: Switchgear and protection standards

• IEEE 80: Substation grounding

National and Regional Codes:

• NEC (NFPA 70) for electrical installations

• OSHA regulations for substation work

• Local utility standards and specifications

• Environmental regulations and permits

Final Session: Project Case Study and Assessment

Comprehensive Design Project:
Complete substation design exercise including:

• Load analysis and transformer sizing

• Bus arrangement selection and justification

• Equipment specification: transformer, circuit breakers

• Protection scheme design and relay selection

• Single-line and three-line diagrams

• Substation layout and plot plan

• Grounding system design

• Protection coordination study

• Cost estimation and project schedule

Assessment Activities:

• Written examination covering substation design and operation

• Practical design exercise evaluation

• Protection scheme development project

• Switching procedure development

• Group presentation: substation design case study

• Interactive Q&A with experienced substation engineers

• Professional Certificate in Substation Design & Operation

• Course evaluation and networking session

Course Benefits and Learning Outcomes

Upon completion, participants will be able to:

• Design transmission and distribution substations per industry standards

• Select appropriate bus arrangements for reliability and cost

• Specify transformers, circuit breakers, and switchgear correctly

• Design protection and control systems comprehensively

• Develop substation layouts with proper clearances

• Conduct testing and commissioning procedures

• Perform safe switching operations and maintenance

• Apply IEC 61850 and modern substation automation

• Manage substation projects from concept to energization

• Ensure compliance with safety and environmental regulations

• Optimize substation design for lifecycle costs

• Troubleshoot operational issues effectively

Training Methodology

This substation engineering course employs:

• Expert instruction from experienced substation engineers

• Comprehensive design examples and calculations

• Real substation project case studies

• Computer-aided design demonstrations

• Equipment videos and virtual tours

• Interactive design workshops

• Standards interpretation and application

• Industry best practices and lessons learned

Course Materials Provided

Participants receive:

• Comprehensive substation design handbook

• Equipment specification templates

• Protection scheme examples and settings

• Design calculation spreadsheets

• Standards excerpts: IEC, IEEE, ANSI

• Substation layout and drawing examples

• Testing and commissioning checklists

• Certificate of Professional Development

Software and Tools Covered

Introduction to design tools:

• AutoCAD for substation layout drawings

• ETAP or SKM for protection studies

• Grounding grid design software

• Project management tools

• Equipment selection databases

Prerequisites

Recommended background:

• Bachelor’s degree in Electrical Engineering

• Understanding of power systems fundamentals

• Knowledge of three-phase AC systems

• Familiarity with electrical equipment

• Basic protection principles helpful

Keywords: substation design, substation operation, substation engineering training, power substation, transmission substation, distribution substation, circuit breaker selection, power transformer, bus arrangement, substation protection, IEC 61850, substation automation, SCADA systems, GIS substation, substation layout, grounding grid design, substation commissioning, switching operations, substation maintenance, electrical substation course, protection coordination