Introduction

Incon was engaged to provide structural verification, certification, and design review services for the Brooklyn Zone Substation Stage 2 project in Victoria. The project involved the augmentation of an existing 66/11kV substation to support increased power demand and future expansion of critical energy infrastructure.

Project
description

The project comprised the structural verification and certification of multiple substation components associated with the Stage 2 upgrade, including:

  • Transformer foundations for upgraded 30/50MVA units
  • Footings for circuit breakers, disconnectors, and post insulators
  • Structural design verification of light mast and NER (Neutral Earthing Resistor) foundations
  • Voltage transformer and associated equipment support structures

The scope involved a detailed structural check, verification calculations, and certification of design drawings submitted for approval, ensuring compliance with project specifications and Australian Standards.


Challenge

The project required a high level of engineering precision and coordination due to:

  • Integration with an existing operational substation, requiring validation of new works without compromising existing infrastructure
  • Multiple equipment types and loading conditions, each requiring independent verification and compliance assessment
  • Strict compliance requirements, including:
    • AS1170 loading standards
    • Importance Level 3 classification
    • 50-year design life
    • High wind loads (Region A5, 46 m/s wind speed)
  • Tight project timelines, with rapid turnaround required for certification and approvals


Solution

We delivered a robust and efficient verification solution through:

  • Comprehensive structural verification calculations for all critical substation footings and support systems
  • Detailed review of design drawings against AS1170 loading criteria, including wind and seismic actions
  • Assessment of foundation adequacy and hold-down systems, ensuring stability under operational and extreme loading scenarios
  • Identification of required design modifications and retrofit recommendations, where necessary, to achieve compliance
  • Preparation and issuance of CPEng-certified structural certificates and stamped drawings, facilitating regulatory approval
  • Efficient coordination with the client team to meet tight submission deadlines and maintain project momentum


Key Engineering Highlights

  • Verification of multiple high-voltage substation foundation systems
  • Designed for 50-year design life and Importance Level 3 infrastructure
  • Wind design based on 46 m/s (Region A5) conditions
  • Delivery of CPEng-certified calculations and drawings
  • Integration with live substation upgrade works


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