ZHM Delivering Three 161kV Substations for Power Infrastructure Development

As a specialist EPC (Engineering, Procurement, and Construction) contractor in the power and metal engineering sector, ZHM  is proud to detail our comprehensive scope as the nominated subcontractor for the design, supply, and installation of three critical 10kV/161kV gas-fired power substation projects in Ghana’s Western Region: the GP-Chirano, GP-Wassa, and GP-Edikan Substations. This project for our client underscores our capability to execute complex, high-voltage infrastructure projects in West Africa, integrating advanced electrical systems from engineering through to commissioning and handover.

Our scope for this three-substation portfolio encompasses the complete lifecycle of substation development:

‌1. Comprehensive Engineering & System Design‌

ZHM is responsible for the detailed engineering of these Air Insulated Switchgear (AIS) substations. This includes reviewing and finalizing layout drawings, preparing single-line diagrams (SLD), and performing critical calculations for structural support, lightning protection (per IEC 62305/GB 50057), and protection relay coordination. Our design adheres to a hybrid of international standards (IEC, IEEE) and Chinese national codes (GB, DL) to ensure robust performance and local compliance.

‌2. Fabrication & Global Supply Chain Management‌

At our factory in Hangzhou, China, we fabricate all galvanized steel support structures, gantry frames, and equipment bases. We procure and manage the supply of a vast array of HV and MV equipment, conducting Factory Acceptance Tests (FAT) before overseeing sea freight logistics to Ghana's Tema Port. Our supply scope for each substation includes:

‌▶High Voltage (161kV) AIS Equipment:‌ SF6 Circuit Breakers (LW36-161, 40kA), Disconnectors (GW16-161DW), Capacitive & Electromagnetic Voltage Transformers (CVT/VT), Current Transformers (CT), and Surge Arresters.
▶‌Medium Voltage (11kV) Systems:‌ Indoor switchgear, aluminum tubular busbars, and 250kVA grounding transformers.
▶‌Substation Automation & Protection:‌ A full digital Substation Automation System (SAS) based on IEC 61850, featuring Bay Control Units (CSI-200E), line protection relays (CSC-103/101), transformer differential protection (CSC-326), and busbar protection (CSC-150).
▶‌Auxiliary Systems:‌ Complete DC power systems (125V), CCTV security surveillance, fire detection & suppression (including FM-200 systems), HVAC, lighting, and Power Line Carrier (PLC) telecommunication.

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3. Turnkey Installation & Rigorous Commissioning‌

Our experienced site teams manage the complete installation sequence, from foundation interface inspection to final energization. This involves:

‌▶Primary Equipment Erection:‌ Precise installation of 161kV AIS components, main power transformers (Owner-Furnished Equipment by TBEA), and all associated buswork (AAAC conductor & tubular bus).
‌▶Secondary System Integration:‌ Installation and wiring of all control, protection, and metering panels, followed by extensive loop checks and secondary injection tests.
‌▶Critical Infrastructure:‌ Installation of main grounding grids (target resistance ≤ 0.5Ω), cable tray & cable pulling systems, and lightning protection networks.
▶‌Integrated Testing:‌ A strict protocol of Site Acceptance Tests (SAT), including insulation resistance (IR) tests, contact resistance measurements, primary injection for CTs, and protection relay functional tests, culminating in a supervised 72-hour continuous load operation test.

‌4. Adherence to Method & Quality‌

Execution follows a detailed ‌Method Statement‌ covering mobilization, safety (HSE protocols per OHSAS 18001), and Quality Assurance aligned with ‌ISO 9001:2015‌. We implement Inspection and Test Plans (ITPs) for every phase, from steel structure galvanizing checks to final pre-energization clearance. All work complies with Ghanaian Grid Code (GRIDCo) and local regulatory requirements.

This project demonstrates ZHM’s integrated EPC solution for high-voltage substations, combining in-house engineering and fabrication with disciplined on-site construction management to deliver reliable power infrastructure that supports Ghana's energy development.

1 3D BIM Model Wassa 161kV Substations

2 Chirano Substation Gantry Frame Inlet Outlet Conduct

3 Wassa Substation Gantry Truss PT Lighting Arrester

4 Chirano Power Plant Substation Bird View

5 Edican Sub Station Interconnection Existing 161kV

7 Bus bar Bay Gantry Frameworks

8 Pipe type Bus Bar Factory Production Inspection

9 Tube Bus Bar Container Loadings Delivery

10 Wassa Substation Layout Plan Drawing

11 Prefabricated Busbar Junction Box Air Box

12 Transformer 3P Oil Immersed Outdoor Step Up Onan Onaf

13 LV Tubular Bus Bar From Power Plant Substation

14 HV Tubular Bus Bar Supporting Insulators

15 Prefabricated High Voltage 161kV Air Insulated Swithgear AIS

16 Telecommunication Equipment PLC System

17 Illumination Lighting System Distribution Board

18 Substation BIM Modeling Wassa LV Power Cable Edican Busbar

19 Substation Prefabricated Steel Structures Container Loading

20 Wassa Chirano Substation Foundation Preparation

21 Gantry Frame Insulator Hardwares Erection

22 Busbar Support Structures Gantry Frames

23 Disconnector Earth Swith SGS Inspection

24 Lighting Surging Arrester Installation

25 Substation Grounding System Cad welding Material Preparation

26 Lighting Prection Tower Polyn Pole System SPD

27 Communication Equipment ABB FOX615 CPU Power STM GE Electric Panels

28 5000A Prefabricated Containerized Breakers

29 Secondary System UPS DC Panel DCS Cabinets

30 Conduct Cable Delivery

31 Insulators Clamps Hardwares Delivery Container Loading

32 Substation Steel Structures Container Loadings

Why ZHM Huawu Metal 161kV Substation Constructions ?

Reliable and Customized Designs	Cutting Edge Designing Process	Free Online Price System	Easy Bolt-by-number Assembly
Over Two Decades of Experience	Value For Money	Unmatched in Quality and Craftmanship	Excellent Customer Service

Would you like to see more information and images of ZHM Huawu Steel's Metal 161kV Substation Constructions? Visit our Photo Gallery.

HOW CAN WE HELP YOU?

ZHM’s world-class team — together with our raw material suppliers and subcontractors — works to solve your most challenging design, engineering, farbrication or construction issues.

Contact ZHM by telephone at +86 135-8815-1981 (wechat and whatsapp) or send us your questions via email to info@zhmsteelworks.com