Design Build Contract for a Complete Sub-Station Upgrade for Local Steel Mill

Project Description

A Local Steel Mill’s existing main substation comprised two 230 kV to 13.8 kV stepdown transformers supplying power to operate production machinery and ancillary electrical requirements for the entire plant. Transformer No. 1 began to generate high levels of acetylene gas and had to be taken offline immediately. Further investigation determined that the transformer could not be repaired. Eaton Electrical Services and Systems Division was awarded a Design-Build contract for a complete substation upgrade which included the installation of two new, customer-supplied transformers.
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Project details:

  • Brownfield
  • Construction
  • Commissioning
  • Design/Build
  • Engineering
  • High Voltage
  • Life Extension/Modernization


  • Medium Voltage
  • Mining-Metals/Minerals
  • Startup
  • Substation
  • Switchgear Upgrade
  • Testing
  • Turnkey

Equipment to be supplied for this project included:

  • 230 kV Bus
  • 230 kV Main Disconnect Switch
  • 230 kV Metering Transformers (PTs & CTs)
  • 230 kV Circuit Switchers
  • 15 kV Switchgear complete with substation Protection


  • 125 VDC Battery System
  • 15 kV Harmonic Filters
  • 15 kV line Reactors for
  • improved Electric Arc Furnace
  • (EAF) performance

The scope of this turnkey substation project included:

  • Electrical and civil engineering including substation design, design of substation structures, control building with full basement for marshaling of MV and control cables, harmonic filters, and application of EAF line reactors
  • Project Management and coordination
  • Equipment Procurement
  • Scheduling
  • Construction
  • Commissioning of the
  • Substation equipment
A major consideration in the implementation of this project was the requirement to maintain plant operations throughout by minimizing both the required number and duration of plant shutdowns.


EAF Filter - Looking East.jpg