RAJASTHAN RAJYA VIDYUT PRASARAN NIGAM LTD.

(Regd. Office: Vidyut Bhavan, Janpath, Jyoti Nagar, Jaipur–302005)

CONSTRUCTION MANUAL FOR SUB STATIONS

Last Updated : 31-1-2008

FOREWORD

The Engineers experienced in the field of Transmission have made this effort to compile the experience gained over the past 40 years in the form of a Manual and make it available to the Engineers and Technical Supervisors of the Company. This is a step forward to disseminate knowledge so that uniform practices and procedures are followed in the construction activities in the Company.

This Manual covers all the activities related to the construction of Sub Stations.

I appreciate the work done by the members of the Committee in preparing and bringing out this Construction Manual for Sub Stations.

I hope that the Manual will be of immense use and reference to the Engineers of the Transmission & Construction Wing.

April, 2007 Jaipur

Shreemat Pandey Chairman & Managing Director Rajasthan Rajya Vidyut Prasaran Nigam Ltd.

Last Updated : 31-1-2008

PREFACE

The construction practices in the transmission wing of RVPN have been built over the past 40 years and passed on from seniors to juniors. The new generation of Engineers, skilled Technical Supervisors and Workmen has, from time to time, constantly updated the construction practices according to the latest developments in the field of Transmission Engineering.

It was felt that the construction practices built over the years be compiled in the form of a Manual and made available to Engineers and Technical Supervisors engaged in the construction activities so that uniform practices and procedures are followed in the Company.

A Committee of the following Engineers experienced in the field of Transmission was assigned the task of preparing the Construction Manual: Shri S. Dhawan, Chief Engineer (MM) Shri B. N. Saini, Superintending Engineer (400 KV Design) Shri Raghuvendra Singh, Executive Engineer (Prot. II) Shri Mohan Singh Ruhela, Executive Engineer (C&M–400 KV GSS), Heerapura Shri A. D. Sharma, Assistant Engineer (Civil – 400 KV Design) Shri Atul Sharma, Assistant Engineer (TLPC) I appreciate the work done by the members of the Committee in preparing and bringing out this Construction Manual for Sub Stations. I am confident that the Manual will be of great help to the Engineers posted in the Transmission & Construction Wing in discharging their duties.

April, 2007 Jaipur

Y. K. Raizada Director (Technical) Rajasthan Rajya Vidyut Prasaran Nigam Ltd.

Last Updated : 31-1-2008

25. 15.CONTENTS Section – I: SITE SELECTION & SUB STATION DESIGN 1. 22. General Instructions Structures Bus Bar and Earth Wire Aluminium Pipe Bus Bar and Joints Power Transformers Circuit Breakers Isolators Current Transformers Capacitor Voltage Transformers (CVT) / Potential Transformers (PT) Lightning Arresters Post / Polycone Insulators Wave Traps Line Matching Unit (LMU) / Line Matching Distribution Unit (LMDU) Capacitor Banks Earthing Cable Laying and Wiring Battery Sets (Valve Regulated Lead Acid / VRLA) DC Panels Battery Chargers Control & Relay Panels LT Panels PLCC Carrier Sets Carrier Protection Couplers PLCC Exchange Commissioning of Sub Station Bibliography 97 99 103 117 121 125 127 129 133 137 141 143 145 87 91 93 95 41 43 47 53 57 71 79 83 Last Updated : 31-1-2008 . 16. 13. 21. 4. 9. Selection of Land Layout Design Safety Clearances Earth Mat Design 5 7 33 35 Section – II: ERECTION. 11. 20. 18. 23. 2. 7. TESTING AND COMMISSIONING 1. 10. 3. 4. 6. 17. 14. 2. 24. 12. 5. 8. 19. 3.

SECTION – I SITE SELECTION & SUB STATION DESIGN Last Updated : 31-1-2008 .

Preferably fairly leveled ground. Easily accessible to the public road to facilitate transport of material. Sufficiently away from areas where police and military rifle practices are held. b) As far as possible rectangular or square in shape for ease of proper orientation of bus – bars and feeders.0 1. 2. and should have the sufficient area for future extension of the buildings and / or switchyard.3 c) d) e) f) g) h) i) 1. REQUIREMENT OF LAND / AREA: The site should have sufficient area to properly accommodate the Sub Station buildings. Free from master plans / layouts or future development activities to have free line corridors for the present and in future. environmentally. 1. This facilitates reduction in leveling expenditure. etc. to permit easy and safe approach / termination of high voltage overhead transmission lines. The site of the proposed Sub Station should not be in the vicinity of an aerodrome. structures.2 1. The distance of a Sub Station from an aerodrome should be maintained as per regulations of the aerodrome authority. As far as possible near a town and away from municipal dumping grounds. This needs meticulous planning. economically and socially optimal and is the best suited to the requirements.5 The site should have as far as possible good drinking water supply for the station staff.CHAPTER – 1 SELECTION OF LAND 1.4 1. Above highest flood level (HFL) so that there is no water logging. The main points to be considered in the selection of site for construction of a Grid Sub Station are given below. fore-sight.1 Last Updated : 31-1-2008 . Approval in writing should be obtained from the aerodrome authority in case the Sub Station is proposed to be located near an aerodrome. skillful observation and handling so that the selected site is technically.1 SELECTION OF SITE: Selection of site for construction of a Grid Sub Station is the first and important activity.0 2. tanneries and other obnoxious areas. Far away from obstructions. The site should be: a) As near the load centre as possible. burial grounds. equipments.

2 The requirement of land for construction of Sub Station including staff colony is as under: S. 3.5 Hectare 2.0 Hectare 6.6 Construction Manual for Sub Stations 2. the requirement should be restricted to the limit mentioned in para 2.3 While preparing proposals for acquisition of private land and allotment of Government land.No. While selecting Government land.2 above. the area of land for respective Grid Sub Stations shall be taken into consideration as mentioned in para 2. Voltage Class of GSS 400 kV 220 kV 132 kV Required Area 20. the requirement may be made liberally but in other cases. where payment is to be made for the land acquisition.0 Hectare 3. 1.2. Last Updated : 31-1-2008 . 2.

2. The entire Sub Station is lost in case of a fault on the bus bar or on any bus bar isolator and also in case of maintenance of the bus bar.0 BUS BAR SCHEMES: The commonly used bus bar schemes at Sub Stations are: a) Single bus bar.4 1. for ‘n’ number of circuits. c) Double bus bar. DOUBLE MAIN AND AUXILIARY BUS BAR ARRANGEMENT: The limitation of double bus bar scheme can be overcome by using additional Auxiliary bus.4. This scheme suffers from the disadvantage that when any circuit breaker is taken out for maintenance.2.e.2. Typical Single Bus Bar arrangement is shown in Annexure – 1. The additional provision of bus coupler circuit (Auxiliary bus) facilitates taking out one circuit breaker at a time for routine overhaul and maintenance without de – energizing the circuit controlled by that breaker as that circuit then gets energized through bus coupler breaker.3 1. this scheme also suffers from the disadvantages that in the event of a fault on the main bus bar or the associated isolator.CHAPTER – 2 LAYOUT DESIGN 1. b) Main and Auxiliary bus bar.. This bus arrangement has been extensively used in 132 kV Sub Stations.2 1. The feeder is transferred to the 1. Bus coupler breaker is also provided so that the circuits can be switched on from one bus to the other on load.3.1 1.1 1. a double bus bar arrangement is provided. it employs ‘n + 1’ circuit breakers. SINGLE BUS BAR ARRANGEMENT: This is the simplest switching scheme in which each circuit is provided with one circuit breaker. the entire substation is lost. Typical Main and Auxiliary Bus Bar arrangement is shown in Annexure -2.2 1.1 1. the associated feeder has to be shutdown. Another disadvantage of this switching scheme is that in case of maintenance of circuit breaker. Typical Double Bus Bar arrangement is shown in Annexure – 3. Each circuit can be connected to either one of these bus bars through respective bus bar isolator. d) Double Main and Auxiliary bus bar e) One and a half breaker scheme. the associated feeder has also to be shutdown.1 Last Updated : 31-1-2008 .3.1.3 1. DOUBLE BUS BAR ARRANGEMENT: In this scheme. As in the case of single bus arrangement. i.1. bus coupler breaker and Auxiliary bus isolators. Each circuit is connected to the main bus bar through a circuit breaker with isolators on both sides and can be connected to the auxiliary bus bar through an isolator.2 1.3. This arrangement offers little security against bus bar faults and no switching flexibility resulting into quite extensive outages of bus bar and frequent maintenance of bus bar isolator(s). MAIN AND AUXILIARY BUS ARRANGEMENT: This is technically a single bus bar arrangement with an additional bus bar called “Auxiliary bus” energized from main bus bars through a bus coupler circuit.1 1. This Bus bar arrangement was generally used in earlier 220 kV sub stations.2 1.3 1.

ONE AND A HALF BREAKER ARRANGEMENT: In this scheme.3 1. ELECTRICAL LAYOUT DRAWING: Typical electrical layout drawings and sectional drawings of 400 kV.1 1. 220 kV and 400 kV sub stations are given at Annexure – 15 to Annexure – 17 respectively. A fault on any one of the bus bars is cleared by opening of the associated circuit breakers connected to the faulty bus bar without affecting continuity of supply.1 3.5.0 2.2 This Bus bar arrangement is generally used nowadays in 220 kV sub stations. Any other equipment / structure / material which may be required for construction of Sub Station as per layout and other requirements and not included in the above typical lists of material are also to be added. Typical One and a Half Breaker arrangement is shown in Annexure – 5.3 2. Similarly. This scheme has been used in the 400 kV substations. therefore. both the bus bars are in service. 220 kV and 132 kV sub stations with different bus bar arrangements generally adopted in RVPN are shown in Annexure – 6 to Annexure – 14. Normally.5.8 Construction Manual for Sub Stations Auxiliary bus during maintenance of its controlling circuit breaker without affecting the other circuits. protective relaying is somewhat more involved as the central (tie) breaker has to be responsive to troubles on either feeder in the correct sequence. the operation is simple.2 1.2 Last Updated : 31-1-2008 .5. However.4.1 3. 1. The lists of material are only typical and cover the general requirement. 1. Typical Double Main and Auxiliary Bus Bar arrangement is shown in Annexure – 4.4.5 1. three circuit breakers are used for controlling two circuits which are connected between two bus bars. each element of the bay has to be rated for carrying the currents of two feeders to meet the requirement of various switching operations which increases the cost. Besides. BILL OF MATERIAL: Lists of material showing the particulars of the material generally required for construction of 132 kV. any circuit breaker can be taken out for maintenance without causing interruption. Load transfer is achieved through the breakers and.0 3. The breaker and a half scheme is best for those substations which handle large quantities of power and where the orientation of out going feeders is in opposite directions.

Layout Design 9 ANNEXURE – 1 Last Updated : 31-1-2008 .

10 Construction Manual for Sub Stations ANNEXURE – 2 Last Updated : 31-1-2008 .

Layout Design 11 ANNEXURE – 3 Last Updated : 31-1-2008 .

12 Construction Manual for Sub Stations ANNEXURE – 4 Last Updated : 31-1-2008 .

Layout Design 13 ANNEXURE – 5 Last Updated : 31-1-2008 .

14 Construction Manual for Sub Stations ANNEXURE – 6 Last Updated : 31-1-2008 .

Layout Design 15 ANNEXURE – 7 Last Updated : 31-1-2008 .

16 Construction Manual for Sub Stations ANNEXURE – 8 Last Updated : 31-1-2008 .

Layout Design 17 ANNEXURE – 9 Last Updated : 31-1-2008 .

18 Construction Manual for Sub Stations ANNEXURE – 10 Last Updated : 31-1-2008 .

Layout Design 19 ANNEXURE – 11 Last Updated : 31-1-2008 .

20 Construction Manual for Sub Stations ANNEXURE – 12 Last Updated : 31-1-2008 .

Layout Design 21 ANNEXURE – 13 Last Updated : 31-1-2008 .

22 Construction Manual for Sub Stations ANNEXURE – 14 Last Updated : 31-1-2008 .

3C) 7. 33 kV Marshalling Kiosk (one for 2 nos. PIS type for 132 kV PIs 20. 5C) 17. X – 15 type for 33 kV Isolators 21. Y – type Column (with stub) 13. 33 kV Current Transformer for feeder (125 – 250 – 500 / 1A. Y – type Column (without stub) 14. bays) Last Updated : 31-1-2008 . 110/√3. AO – 5 type for LA’s / CT’s / Bus CVT’s 19. BT – 6 type Column 4. 132 / 33 kV Power Transformer 2. R – type Column (with stub) 10. 132 kV Lightning Arrester 10. 22 kV Post Insulators 21. X – type Column 12. GD type (10. 132 kV Isolator with Earth Blade 4.4 Meters for 33 kV) 16. BT – 7 type Column 5. 3C) 8. Z – type Column (with stub) 15.415 kV. 132 kV Wave Trap 11. BT – 1 type Column 2. 132 kV Isolator without Earth Blade 3. No. 33 kV Lightning Arrester 20. BO – 1 (T) type for 132 kV Tandem Isolators 18. complete. 33 kV Current Transformer for transformer (250 – 500 / 1A. 33 kV CT type B. 132 kV Current Transformer for transformer (125 – 250 – 500 / 1A. washers. Structures / Beams with nuts. GF – type Beam (5. 33 / 0.Layout Design 23 Annexure – 15 LIST OF MATERIAL (TYPICAL) FOR CONSTRUCTION OF 132 kV GRID SUB-STATION S. 33 kV Isolator without Earth Blade 14. BB – 1 type Beam 6. P – type Column 7. 33 kV Potential Transformer (110/√3. 33 kV Horn Gap Fuse Set 23. etc. 110/√3) 19. 132 kV Capacitor Voltage Transformer (110/√3. 250 KVA Station Transformer 22. 110/√3) 9. 33 kV Circuit Breaker with structure (110 V DC) 16. Particulars A. 132 kV Current Transformer for feeder (250 – 500 / 1A.0 Meters) Beam 11. 132 kV Marshalling Kiosk 13. 2C) 18. 132 kV Post Insulators 12. BT – 4 type Column 3. 132 kV Circuit Breaker with structure (110 V DC) 6. 1. 33 kV Isolator with Earth Blade 15. Outdoor Equipment 1. BO – 1 type for 132 kV Isolators 17. Q – type Column (with stub) 8. 132 kV Tandem Isolator 5. bolts. Q – type Column (without stub) 9.

3 core × 2. mm. 1A) 6. feeders (110V. 2. G.15 mm. 132 kV Feeder Control & Relay Panel (110 V.5 sq. P.24 Construction Manual for Sub Stations S. LT Power Cable (Aluminium) 1. Control Room Equipment 1. 110 Volts. Others / Miscellaneous 1. Clamps for Zebra to Panther 14. 5. 1A) 2. ACSR Zebra Conductor 8. S. mm. 200 AH Battery Set 7. 200 AH Battery Charger 8. G. mm. P. Round 25 mm. 132 kV side of Transformer Control & Relay Panel (110 V. Single Suspension Hardware for Panther 5. T. dia. 45 KN 7. Flat 50 × 6 mm. 11 KV Disc Insulators. No. mm. G. 110 Volts D. Fire Fighting Equipment 1. L. Earthing Material 1. Last Updated : 31-1-2008 . P. Channel 100 × 50 × 6 mm. 2. mm. M. 6. P. Clamps for Zebra to Zebra 13. I .15 mm GSS Earth wire 18. M. mm. ACSR Panther Conductor 9. G. 4. F. T – Clamps for Zebra to Panther 11. Clamps for Panther to Panther 15. C. 132 kV Bus Coupler Control & Relay Panel (110V. 1A) 3. Single Tension Hardware for Single Zebra (Bolted type) 2. G. C. S.Clamps for Zebra 16. Copper Control Cables 1. Bus Bar Material 1. 33 kV side Control & Relay Panel for Transformer & Bus Coupler (110V. Distribution Board 9. T – Clamps for Zebra to Zebra 10. mm. 4 core × 2. 3. Tension Hardware for 7 / 3. I .Clamps for Panther 17. 1A) 4. Flat 50 × 10 mm. 120 KN 6. Distribution Board (110 V DC) D. 3½ core × 300 sq. 18 / 16 core × 2.5 sq.5 sq.5 sq. D. T – Clamps for Panther to Panther 12. Single Suspension Hardware for Single Zebra 4. 12 / 10 core × 2. Particulars C. M. 3. 11 KV Disc Insulators. 33 kV Feeder Control & Relay Panel for two nos. M. 2. 4 core × 4 sq. 110 Volts. Clamps for 7 / 3. Single Tension Hardware for Panther (Bolted type) 3. type. H. GSS Earth wire 19. 1A) 5.15 mm. S. CO2 type. 2. 6 core × 2. Copper Earth Bond I. 7 / 3. S. P.5 sq. Earth wire E. P. P.

AO – 3 type for 220 kV CT’s 15. 220 kV Post Insulators 12. AT – 3 type Column 3. AB – 1 type Beam 7. etc. AO – 1 type for 220 kV Isolators 13. AT – 8 type Column 6. AO – 5 type for 220 kV LA’s & for 132 kV CT’s. 132 kV Isolator without Earth Blade 14. PIS type for 220 kV & 132 kV PI’s B. 220 kV Lightning Arrester 10. 132 kV Circuit Breaker with structure (220 V DC) 17. BO – 1 (T) type for 132 kV Tandem Isolators 19. 110/√3) 9. AT – 6 type Column 5. BT – 6 type Column 10. complete. 220 kV Isolator with Double Earth Blade 5. 1. Structures / Beams with nuts. 132 kV Current Transformer (250 – 500 / 1A. Outdoor Equipment 1. bolts. washers. 220 kV Isolator without Earth Blade 3. AO – 4 type for 220 kV CVT’s 16. BT – 7 type Column 11. 33 / 0. 220 kV Capacitor Voltage Transformer (110/√3.Layout Design 25 Annexure – 16 LIST OF MATERIAL (TYPICAL) FOR CONSTRUCTION OF 220 kV GRID SUB-STATION S. CVT’s / PT’s.415 kV. AT – 1 type Column 2. AO – 1 (T) type for 220 kV Tandem Isolators 14. 220 kV Isolator with Earth Blade 4. 220 kV Circuit Breaker with structure (220 V DC) 7. 250 KVA Station Transformer Last Updated : 31-1-2008 . 132 kV Isolator with Earth Blade 15. 5C) 8. BO – 1 type for 132 kV Isolators 18. 220 kV Wave Trap 11. BT – 4 type Column 9. 220 kV Marshalling Kiosk 13. 132 kV Tandem Isolator 16. Particulars A. AT – 4 type Column 4. 220 kV Current Transformer (400 – 800 / 1A. BB – 1 type Beam 12. No. 132 kV Lightning Arrester 20. 220 kV Tandem Isolator 6. 132 kV Marshalling Kiosk 23. 220 / 132 kV Power Transformer 2. 110/√3) 19. 4C) 18. LA’s 17. 132 kV Capacitor Voltage Transformer (110/√3. 132 kV Post Insulators 22. BT – 1 type Column 8. 132 kV Wave Trap 21.

Earth wire E. 220 kV Bus Coupler Control & Relay Panel (220 V DC. 6 core × 6 sq. 4 core × 2. 7. Bus Bar Material 1. 2. 220 kV side of Transformer Control & Relay Panel (220 V DC. Clamps for Panther to Panther (P – P) 19. 4 core × 4 sq.Clamps for Zebra 20. G. GSS Earth wire 23. mm. Single Suspension Hardware for Single Zebra 6. 132 kV side of Transformer Control & Relay Panel (220 V DC. 18 / 16 core × 2.00 mm. G. Spacer T – Clamps for Double Zebra to Panther (ZZ – P) 13. Clamps for 7 / 4. P. Earthing Material 1. L. Distribution Board (220 V DC) D.00 mm. M. 1A) 3. 120 KN 8. dia. ACSR Zebra Conductor 10.00 mm GSS Earth wire 22. 1A) 7. 11 kV Disc Insulators. P. Single Suspension Hardware for Panther 7. P. Single Tension Hardware for Double Zebra (Bolted type) 2. 1A) 5.5 sq. I . No. Copper Control Cables 1. T – Clamps for Panther to Panther (P – P) 16. 6 core × 2.5 sq. 7 / 4. mm. LT Power Cable (Aluminium) 1. 220 Volts. 132 kV Bus Coupler Control & Relay Panel (220 V DC. P. Single Suspension Hardware for Double Zebra 5. Spacer T – Clamps for Double Zebra to Zebra (ZZ – Z) 12. mm. Clamps for Zebra to Panther (Z – P) 18. mm. C. Particulars C. 400 AH Battery Charger 9. mm. 220 Volts. S.5 sq. ACSR Panther Conductor 11. Last Updated : 31-1-2008 . S. Clamps for Zebra to Zebra (Z – Z) 17. Flat 50 × 6 mm. 5. S. 11 kV Disc Insulators. 6. P. G. 220 kV Feeder Control & Relay Panel (220 V DC. mm. 3. F. 12 / 10 core × 2. M. mm. Single Tension Hardware for Single Zebra (Bolted type) 3. Flat 50 × 12 mm. G. 1A) 6. Round 28 mm. I . Tension Hardware for 7 / 4. T – Clamps for Zebra to Panther (Z – P) 15. Distribution Board 10. Control Room Equipment 1. 4. 220 Volts D.Clamps for Panther 21. 400 AH Battery Set 8. T. Single Tension Hardware for Panther (Bolted type) 4. P. mm. M. T – Clamps for Zebra to Zebra (Z – Z) 14.26 Construction Manual for Sub Stations S. 1A) 4. 3. 2. 3 core × 2. 132 kV Feeder Control & Relay Panel (220 V DC. 1A) 2. 3½ core × 300 sq.5 sq.5 sq. 70 KN 9. G.

2. M. Particulars H. Channel 100 × 50 × 6 mm. No. Copper Earth Bond I. type 2. C. S. CO2 type Last Updated : 31-1-2008 . P. D.Layout Design 27 S. Fire Fighting Equipment 1. Others / Miscellaneous 1.

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Construction Manual for Sub Stations

Annexure – 17 LIST OF MATERIAL (TYPICAL) FOR CONSTRUCTION OF 400 kV GRID SUB-STATION S. No. Particulars A. Structures / Beams with nuts, bolts, washers, etc. complete. 1. EhT – 1 type Column 2. EhB – 1 type Beam 3. AT – 1 type Column 4. AT – 3 type Column 5. AT – 4 type Column 6. AT – 6 type Column 7. AT – 8 type Column 8. AB – 1 type Beam 9. 400 kV Isolator Structure 10. 400 kV CT Structure 11. 400 kV CVT Structure 12. 400 kV LA Structure 13. 400 kV PI Structure (8.0 Meter Bus Height) 14. 400 kV PI Structure (10.0 Meter Bus Height) 15. 400 kV PI Structure (13.0 Meter Bus Height) 16. 400 kV Wave Trap Structure 17. AO – 1 type for 220 kV Isolators 18. AO – 1 (T) type for 220 kV Tandem Isolators 19. AO – 3 type for 220 kV CT’s 20. AO – 4 type for 220 kV CVT’s 21. AO – 5 type for 220 kV LA’s 22. PIS type for 220 kV PI’s 23. 33 kV PT structure 24. 33 kV PI structure for PI and Horn Gap Fuse B. Outdoor Equipment 1. 400 / 220 kV Power Transformer 2. 400 kV Isolator with Earth Blade 3. 400 kV Isolator with Double Earth Blade 4. 400 kV Isolator with Double Earth Blade (Individual Pole Operated) 5. 400 kV Circuit Breaker with structure (220 V DC) 6. 400 kV Current Transformer (500 – 1000 – 2000 / 1A, 5C) 7. 400 kV Capacitor Voltage Transformer (110/√3 V , 110/√3 V, 110/√3V) 8. 400 kV Lightning Arrester 9. 400 kV Polycone Insulators with corona ring 10. 400 kV Wave Trap (Pedestal Type) 11. 400 kV Marshalling Kiosk 12. 220 kV Isolator without Earth Blade 13. 220 kV Isolator with Earth Blade 14. 220 kV Isolator with Double Earth Blade 15. 220 kV Tandem Isolator 16. 220 kV Circuit Breaker with structure (220 V DC) 17. 220 kV Current Transformer (500-1000-2000 / 1A, 5C) 18. 220 kV Capacitor Voltage Transformer (110/√3 V, 110/√3V)

Last Updated : 31-1-2008

Layout Design

29

Particulars 220 kV Lightning Arrester 220 kV Wave Trap 220 kV Polycone Insulators 220 kV Marshalling Kiosk 52 kV Potential Transformer (110/√3 V, 110/√3V) for tertiary winding of Transformer 24. 33 / 0.415 kV, 630 kVA Station Transformer 25. 22 kV Post Insulators 26. 33 kV Horn gap Fuse 27. Junction Box 28. WCSM 90 / 30 mm insulation for 33 kV pipe bus with tube roll C. Control Room Equipment (220 V DC, 1 Amp.) 1. 400 kV Control Panel for line, Tie CB and Transformer (One and a Half Breaker Scheme) 2. 400 kV Relay Panel for 400 kV line 3. 400 kV Relay Panel for 400 kV Tie CB 4. 400 kV Relay Panel for 400 kV side of transformer 5. 400 kV Bus Bar Protection Relay Panel 6. 220 kV Control Panel for 220 kV side of transformer 7. 220 kV Control Panel for 220 kV feeders 8. 220 kV Control Panel for 220 kV Bus Coupler 9. 220 kV Relay Panel for 220 kV side of transformer 10. 220 kV Relay Panel for 220 kV feeders 11. 220 kV Relay Panel for 220 kV Bus Coupler 12. 220 kV Bus Bar Protection Relay Panel 13. Disturbance Recorder 14. Event Logger Panel 15. 220 Volts, 600 AH Battery Set 16. 220 Volts, 600 AH Battery Charger 17. 220 Volts D. C. Distribution Boards 18. L. T. Distribution Boards 19. 220 V DC / 240 V AC Inverter (2.5 kVA) 20. Master and Slave Clock System (1 No. Master and 6 Nos. Slave) 21. Air Conditioning system 22. Mulsifier Fire fighting System 23. Synchronizing Panel / Trolley D. Bus Bar Material a) 400 kV Side: 1. Double Tension Hardware for double Moose 2. Single suspension Hardware for double Moose (Dropper Type) 3. Single suspension Hardware for double Moose (Jumper Type) 4. 120 KN Disc Insulators (Antifog type) 5. Spacer for Double Moose (Rigid type) 6. Spacer for Double Moose (Flexible type) 7. T – Clamp for Moose 8. Double Moose to 114.2 mm dia. Aluminium pipe clamp (Vertical & Horizontal take off) 9. 400 kV Isolator clamp for Double Moose

S. No. 19. 20. 21. 22. 23.

Last Updated : 31-1-2008

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Construction Manual for Sub Stations

S. No. Particulars 10. 400 kV Isolator clamp for 114.2 mm dia. Aluminium pipe (Expansion type) 11. 400 kV CT clamp for 114.2 mm dia. Aluminium pipe (Expansion type) 12. 400 kV CB clamp for 114.2 mm dia. Aluminium pipe (Expansion type) 13. 400 kV PI clamp for 114.2 mm dia. Aluminium pipe (Expansion type) 14. 400 kV PI clamp for 114.2 mm dia. Aluminium pipe (Rigid type) 15. 400 kV PI clamp for 114.2mm dia. Aluminium pipe (Sliding type) 16. 400 kV LA clamp for Double Moose 17. 400 kV CVT clamp for Double Moose 18. 400 kV Wave Trap clamp for Double Moose 19. 114.2 mm dia. Aluminium pipe 20. Corona End Shield for 114.2 mm dia. Aluminium pipe 21. Angular Connector for 114.2 mm dia. Aluminium pipe, 20 Deg. 22. Angular Connector for 114.2 mm dia. Aluminium pipe, 80 Deg. 23. Angular Connector for 114.2 mm dia. Aluminium pipe, 90 Deg. 24. Angular bend Coupler for 114.2 mm dia. Aluminium pipe, 110 Deg. 25. Angular bend Coupler for 114.2 mm dia. Aluminium pipe, 135 Deg. 26. Straight Run Coupler for 114.2 mm dia. Aluminium pipe 27. Transformer clamp for 400 kV Bushing for Double Moose b) 220 kV Side: 1. Double Tension Hardware for Quadruple Zebra 2. Double Tension Hardware for Double Zebra 3. Single Tension Hardware for Zebra 4. Single Suspension Hardware for Quadruple Zebra (Jumper type) 5. Single Suspension Hardware for Double Zebra (Dropper type) 6. Single Suspension Hardware for Double Zebra (Jumper type) 7. Single Suspension Hardware for Single Zebra 8. 70 KN Disc Insulators (Antifog type) 9. Spacer for Quadruple Zebra 10. Spacer for Double Zebra 11. P. I .Clamps for Double Zebra 12. T – Connector; Quadruple Zebra to Quadruple Zebra 13. T – Connector; Quadruple Zebra to Double Zebra 14. Spacer T – Clamps for Double Zebra to Zebra (ZZ – Z) 15. T – Clamp; Zebra to Zebra 16. P. G. Clamps for Zebra to Zebra (Z – Z) 17. Transformer clamp for 220 kV Bushing for Double Zebra 18. LA Clamp for Double Zebra 19. LA Clamp for Single Zebra 20. CVT Clamp for Single Zebra 21. CT Clamp for Double Zebra 22. CT Clamp for Single Zebra 23. CB Clamp for Double Zebra 24. Isolator Clamp for Double Zebra

Last Updated : 31-1-2008

mm. 27. 22 kV PI Clamp for 72. 25. mm. 2. S. G. 28. S. mm. M.5 sq.03 mm dia. Others / Miscellaneous 1. 18 / 16 core × 2. Flat 75 × 12 mm 4. mm. Clamps for 7 / 4. 2. 5. Copper Earth Bond I. Earth wire 33 kV Side: Transformer clamp for 52 kV Bushing for 72.5 sq. 2. 6. mm.5 sq. 7.03 mm dia. 12 / 10 core × 2. CO2 type S. C. 6 core × 2. mm. Flat 100 × 12 mm. Aluminium pipe (Expansion type) 4. 5.5 sq. S. dia. mm.Layout Design 31 Particulars ACSR Conductor ‘ZEBRA’ Tension Hardware for 7 / 4. Flat 50 × 12 mm. 3½ core × 300 sq. Flat 50 × 6 mm.5 sq. LT Power Cable (Aluminium) 1. No. Channel 100 × 50 × 6 mm. 3.00 mm. P. S. 3. G.00 mm GSS Earth wire 7 / 4. mm. 52 kV PT Clamp for 72. Aluminium pipe (Expansion type) 3. Aluminium pipe (Rigid type) E. c) 1. M. M. Last Updated : 31-1-2008 . type 2. 22 kV PI Clamp for 72. 3 core × 2.03 mm dia. 3½ core × 95 sq. Round 40 mm. 26. 4.00 mm. M. Earthing Material 1. Copper Control Cables (FRLS) 1. D. I. S. Aluminium pipe (Expansion type) 2. mm.03 mm dia. H. Fire Fighting Equipment 1. 4 core × 2. 6 core × 6 sq. 2. GSS Earth wire P. M. G. F. 4 core × 4 sq.

32 Construction Manual for Sub Stations Last Updated : 31-1-2008 .

For safety of personnel moving in the switchyard with tools & plant. effect of short circuits. The Table below gives the minimum values of clearances required for Sub Stations up to 765 kV: Table for Minimum Clearance Switching Impulse Voltage (kVp) Nominal System Voltage (kV) Highest System Voltage (kV) Lightning Impulse level (kVp) Ground Clearance* (mm) 3700 3700 4600 4600 5500 5500 8000 13000 Safety Clearances (mm) 2600 2800 3700 3800 4300 4600 6400 10300 Minimum clearances$ (mm) Between Phase and Earth 178 320 1100 1300 1900 2100 3400 -6400 -Between Phases 229 320 1100 1300 1900 2100 -4200 -9400 1.25 percent per 100 Meters is to be applied for increasing the air clearance for altitudes more than 1000 Meters and up to 3000 Meters. Last Updated : 31-1-2008 .CHAPTER – 3 SAFETY CLEARANCES 1. 2) “Safety Clearance” is the minimum clearance to be maintained in air between the live part of the equipment on one hand and earth or another piece of equipment or conductor (on which it is necessary to carry out the work) on the other.1 SAFETY CLEARANCES: The various equipments and associated / required facilities have to be so arranged within the substation that specified minimum clearances are always available from the point of view of the system reliability and safety of operating personnel. These include the minimum clearances from live parts to earth. Notes: 1) The values in the Table above refer to an altitude not exceeding 1000 Meters and take into account the most unfavourable conditions which may result from the atmospheric pressure variation. It must be ensured that sufficient clearance to ground is also available within the Sub Station so as to ensure safety of the personnel moving about within the switchyard. temperature and moisture.0 1. etc. between live parts of adjacent phases and sectional clearance between live parts of adjacent circuits / bays. A correction factor of 1. wind effects and safety of personnel.2 11 33 132 220 400 12 36 145 245 420 70 170 550 650 950 1050 1425 ----1050 (Ph – E) 1575 (Ph – Ph) 1550 (Ph – E) 2550 (Ph – Ph) 765 800 2100 $ * These values of air clearances are the minimum values dictated by electrical consideration and do not include any addition for construction tolerances.

the following safety working clearances shall be maintained for the bare conductors and live parts of any apparatus in any Sub Stations. Nominal System Voltage (kV) 11 33 132 220 400 765 Highest System Voltage (kV) 12 36 145 245 420 800 Safety Working Clearance (mm) 2600 2800 3700 4300 6400 10300 Notes: i) The above values are valid for altitudes not exceeding 1000 Meters. 1956. 6.3 As per Rule 64 (2) of the Indian Electricity Rules. 2.34 Construction Manual for Sub Stations 1. “Safety Working Clearance” is the minimum clearance to be maintained in air between the live part of the equipment on one hand and earth or another piece of equipment or conductor (on which it is necessary to carry out the work) on the other.25 percent per 100 Meters is to be applied for increasing the clearance for altitudes more than 1000 Meters and up to 3000 Meters. 1. 5. which is the height of lowest point on the insulator (where it meets the earthed metals) from the ground. iii) Last Updated : 31-1-2008 . excluding over head lines of HV and EHV installations: Table for Safety Working Clearance Sl. 4. ii) The above safety working clearances are based on an insulator height of 2440 mm. 3. A correction factor of 1. No.

1 2. which is the maximum value of potential difference between a point on the ground and a point on an object likely to carry fault current such that the points can be touched by a person.0 1. MEASUREMENT OF EARTH RESISTIVITY: Weather Conditions: The resistivity of earth varies over a wide range depending on its moisture content. should also be within safe limits. is then selected to obtain clear readings. An appropriate range on the instrument.1 BASIC REQUIREMENT: Provision of adequate earthing system in a Sub Station is extremely important for the safety of the operating personnel as well as for proper system operation and performance of the protective devices.2 To meet these requirements.0 (ONE) Ohm. The neutral points of different voltage levels of transformers & reactors are separately earthed at two different points.CHAPTER . should be within safe limits. avoiding the two ends of the scale as far as possible.0 2. The Step Potential. advisable to conduct earth resistivity tests during the dry season in order to get conservative results. none of these parts is at a potential higher than that of the earthing mat.2 Last Updated : 31-1-2008 . Touch Potential.3 1. b) c) 1.4 2. The earth resistance Megger is placed on a steady and approximately level base. Test Procedure: Four electrodes are driven in to the earth at equal intervals s along a straight line in the chosen direction. The primary requirements of a good earthing system in a Sub Station are: a) The impedance to ground should be as low as possible but it should not exceed 1. therefore.4 EARTH MAT DESIGN 1. 1. The depth of the electrodes in the ground shall be of the order of 30 to 50 cm. an earthed system comprising of an earthing mat buried at a suitable depth below ground and supplemented with ground rods at suitable points is provided in the Sub Stations. All the structures & equipments in the Sub Station are connected to the earthing mat so as to ensure that under fault conditions. It is. which is the maximum value of the potential difference possible of being shunted by a human body between two accessible points on the ground separated by the distance of one pace (which may be assumed to be one metre). the link between terminals P1 and C1 is opened and the four electrodes are connected to the instrument terminals as shown in the figure. Each of these earthed points should be interconnected with the station earthing mat.

25 and 50 metres.2 Last Updated : 31-1-2008 . along with a sketch showing the directions in which earth resistivity readings have been taken.3 2.1 Testing Soil Uniformity. The horizontal and vertical variation may be detected by repeating the tests at atleast 6 (Six) different location with a number of different electrode spacings. increasing from 1 metre to 50 metres in the steps of 1. 10. shall be submitted to the Superintending Engineer (400 KV Design) for designing the earth mat. It is desirable to get information about the horizontal and vertical variations in earth resistivity over the site under consideration. 5. 2. A diagram showing the typical layout for earth resistivity measurement in 6 directions is enclosed.36 Construction Manual for Sub Stations The resistivity is calculated from the equation given below: ρ = 2π s R where ρ = resistivity of soil in ohm – metre.3. These readings. 15. 2.3. and R = Megger reading in ohms. s = distance between two successive electrodes in metres.

25 M 7.3. 15 M 6. 2M 3.3 An example of the format in which the earth resistivity readings are to be recorded is given below. Last Updated : 31-1-2008 . 2M 3. 50 M Similarly for Direction 3 to Direction 6. 15 M 6. 1M 2. 25 M 7. Sl. 1M 2. 50 M Direction 2 1. 10 M 5. Electrode Spacing Megger Reading in Ohms Earth Resistivity in Ohm – metres Remarks Direction 1 1. 5M 4. 10 M 5. No. 5M 4.Earth Mat Design 37 2.

38 Construction Manual for Sub Stations Last Updated : 31-1-2008 .

TESTING & COMMISSIONING Last Updated : 31-1-2008 .SECTION – II ERECTION.

Last Updated : 31-1-2008 .

wherever necessary.Charge shall submit a requisition to the Engineer In . testing and commissioning of sub station equipment.0 12.charge of the GSS stating the date.1 GENERAL INSTRUCTIONS 1. etc.0 11.0 9. circuit breaker poles. Wherever it is necessary to avail shutdowns of energized circuits for carrying out any work. The slings should be of sufficient length to avoid any damage to insulator or other fragile equipments due to excessive swing.0 Transportation and unloading of the sub station material and equipment at the location shall be done in a safe manner so that they are not damaged or misplaced. All support insulators. on which work is to be carried out. earth wire. has been done. After completion of the erection work. The Work – In – Charge shall ensure that the work is completed within the requisitioned time. etc. The services of the manufacturer’s Engineer. time and duration of the shutdown and the section / portion which is to be kept out of circuit during the shutdown.0 8. etc. shall be returned to the store. effective earthing must be ensured for safety against induced voltages so that work can be carried out without any danger / hazard to the workmen. testing and commissioning manual / instructions procedures of the manufacturer. They should be checked for breakages of strands before being used for the erection of equipments.0 13. Mulmul cloth shall be used for cleaning the inside and outside of hollow insulators. All the material and equipment shall be checked as per Bill of Material (BOM).0 4.CHAPTER . The Work – In – Charge shall ensure that the portion of the switchyard under shutdown has been isolated and that effective earthing of the equipment / bus bar.0 Last Updated : 31-1-2008 .0 3. etc.0 6. 2. may be utilized for erection.0 7. should of sufficient strength to take the load of the equipment to be erected.0 10. Erection of equipment shall be carried out as per and in the manner prescribed in the erection. All unusable cut lengths of material such as conductor. Sling ropes. the Work – In . aluminium pipes. Whenever the work is required to be got done at the existing GSS where the adjacent portions may be charged. templates. scratching by sling ropes. all surplus material including bolts and nuts.0 5. shall not be treated as wastage and shall also be deposited in the store. Transformer bushings and other fragile equipment shall preferably be handled carefully with cranes having suitable boom length and handling capacity.

42 Construction Manual for Sub Stations Last Updated : 31-1-2008 .

5.5 10.5 20. spanners. 6. jacks.0 / 14. 3. winches.5 15.5 12. AB C.0 2. tackles.0 / 14.6 (Width) 4.1 1.2 (Width) 2. 10. The following are required to be made available to the workmen for erection of sub station structures / beams and equipment structures: i) ii) iii) Drawings and bills of material of structures / beams / equipment structures. 7. etc.5 / 7. BT6 BT7 BB P Q R GD Column with Peak Column without Peak Column with Peak and Beams at two levels for Bus Bar stringing Column without Peak Column with Peak Beam Peak Column Extension Beam 16.3 (Width) A.5 7.0 / 7.2 STRUCTURES 1.CHAPTER .5 12. EHT1 2. 1.2 GENERAL INSTRUCTIONS: The structure material shall be stacked member / item wise. 132 kV Structures: BT1 BT3 BT4 Column with Peak Column without Peak Column with Peak and Beams at two levels for Bus Bar stringing Column without Peak Column with Peak Beam 20. Templates of structures.0 10.1 TYPE OF STRUCTURES: The types of structures generally used at sub stations are given below: Sl.0 / 11. ropes.0 / 20.0 (Width) Last Updated : 31-1-2008 . AT6 5.5 3.5 15. 2. 2. 1. T & P such as levelling instruments.0 / 11.0 / 14. derrick.0 / 9.5 25. EHB B. 400 kV Structures: 1.0 / 11.0 1.5 and 9.0 / 7.5 8. No. 220 kV Structures: AT1 AT3 AT4 Column with Peak Beam 4.5 16.5 and 7. Name of Structure Type of Structure Height of Column / Height of Conductor (Meters) 27. 3.5 12. 8.0 / 9. 9. 2.5 16. AT8 6.

5 3. washers. The length of the foundation bolts above the template shall be sufficient so that all parts of the base plate assembly of the structure. along with the foundation bolts tightened on it with nuts on both sides. The template is levelled & centered with reference to its location on the foundation. Name of Structure Type of Structure Height of Column / Height of Conductor (Meters) 33 kV and 11 kV Structures: X Y Z GF – 5. 132kV. PI Structure 220 kV Isolators 220 kV Tandem Isolators 220 kV CT 220 kV CVT 220 kV LA & 132 kV CT. 1. the assembled lower part of the structure is placed on the foundation. AO1 2. X – 15 9. LA 132 kV Isolator 132 kV Tandem Isolator 33 kV & 11kV Isolators 33 kV & 11kV Tandem Isolators 33 kV & 11kV CT.1 SETTING OF STUB / FOUNDATION BOLTS.6 (Width) Equipment Structures: 1.2 3. This is levelled & centered with reference to its location on the foundation. the following points should be checked: 3. CVT / PT. shall be placed on the foundation. AO1 (T) 3. X – 15 (T) 10. The stubs / lowest member shall thereafter be grouted ensuring that there is no displacement during the placing of the concrete and use of vibrator.3 3. In case of structures with stubs. In case of structures in which the lowest member is used as a stub.6 Peak Column Extension Beam for 33 kV Beam for 11 kV 1. nuts and lock nuts can be tightened fully and 2 – 3 threads are left above the lock nut. 5. 4.0 5. the template with stubs shall be placed on the foundation. 3. AO5 6. E.44 Construction Manual for Sub Stations Sl. 33 kV & 11 kV PI ------------ 3. No. LEVELLING AND GROUTING: In case of structures with foundation bolts. CT Structure 11. PT 220 kV. the template. 2. BO1 7. D.4 GF – 4. The foundation bolts shall thereafter be grouted ensuring that there is no displacement during the placing of the concrete and use of vibrator. While levelling and centering the structure / template.4 Last Updated : 31-1-2008 . AO4 5.0 3. BO1 (T) 8.5 5.4 (Width) 4. AO3 4.5 / 5.

0 4. The two opposite sides are then connected together with cross members. as required. particularly structures which are to be connected together. Section Method: This method is used for large and heavy structures when crane facility is available. The two faces / sides of the complete structure are assembled on the ground and then erected. for example. The last lift raises the top of the structure. ii) Section method. On sloping or uneven ground.3.3 4. Alternatively.3. Distance of centre line of the structure from the center line of other structures or from a reference point.3. In case where the major sections of the structure have been assembled. the first face of the second section is erected.3.3 4.3 4.1 4. by a common beam. After the assembly is complete.2 4.Structures 45 a) b) c) d) Level of structure / template with reference to the finished foundation level or the ground level.1 4.5 4. The structure members are kept on ground serially according to erection sequence so that they can be sent up conveniently.1 4. A mobile crane is used for erecting the structures. The complete structure is assembled in a horizontal position near its location. 4. the structure is picked up from the ground with the help of a crane and set on its foundation. which are as below: i) Ground assembly method. This method consists of erecting the structure member by member. Centre to centre distance between structures. suitable packing is provided in the lower level area before or during assembly.3. Ground Assembly Method: This method is used for erection of equipment structures and is the preferred method for erection of sub station structures when crane facility is available. One side is held in place with props or rope guys while the other side is being erected. the bracings on the other two sides are bolted up.4 4. After the structure top is erected and all side bracings have been bolted up.2. This method consists of assembling the structure on the ground and erecting it as a complete unit. iii) Built up method or Piecemeal method. the two faces / sides of the major sections of the structure are assembled on the ground and the same are erected as units.1 ERECTION OF STRUCTURES: Method of Erection: There are mainly three methods of erection of structures. After the two opposite faces have been erected. 4. all the guys are thrown off. The level of the structure / template with reference to level of other similar structures.4 4.2 4.4.2.2 4.2 Last Updated : 31-1-2008 . to eliminate / minimize stress on the structure members. Each assembled side is then lifted clear of the ground with the crane and is lowered into position on its foundation or fitted on to stubs or foundation bolts which are already grouted.2.4.4 4.2. Built up method or Piecemeal method: This method is used for large and heavy structures when crane facility is not available.

5 4. All bolted connections shall be well tightened using spring washers & then punched at three points on the circumference of the bolt. The ends of the beam are connected to the column as per fixing arrangement provided on the columns.4.6 5. The bracings of the upper and lower faces of the beam are then raised up and fitted.46 Construction Manual for Sub Stations 4.3 The erection progresses from the bottom upwards. The four main corner leg members of the first section of the structure are first erected. If these have been assembled on the ground. The columns shall be truly vertical and the beams truly horizontal after erection. Each face of the beam is raised with the help of crane or using derricks which are placed on the top of the already erected structures on both the sides of the beam. The derrick is thus moved up as the structure grows. 4.0 8. The work of erection of beams on erected columns and erection of equipment on erected structures shall not be taken up until these have been checked for tightening of the bolts & nuts.4. For assembling the second section of the structure.4. a derrick is placed on one of the corner legs. then they are lifted up as a unit.2 5.0 7. Measures taken to bring the column to verticality and beam to horizontality should not result in strain on the structure members so as to cause distortion / bending of the members. The leg members and bracings of this section are then hoisted and assembled.0 Last Updated : 31-1-2008 . The derrick is then shifted to the corner leg members on the top of second section to raise the parts of third section of the structure in position for assembly. Single or multi – way pulleys with polypropylene / steel ropes are used as per load requirement. This process is continued till the complete structure is erected. ERECTION OF BEAMS: The two faces of the beam are assembled on the ground.0 5. This derrick is used for raising parts of second section.3 6.4 4.4.1 5. The cross bracings of the first section are raised one by one and bolted to the already erected corner leg angles.

Aluminium pipe 114. 15. 220 kV Auxiliary Bus 6. 220 kV overhead bus & droppers in all bays. 11 kV Main Bus 16.2 mm dia. Description No. 132 kV overhead bus & droppers in all bays. 400 kV overhead bus & droppers in all bays. overhead bus and droppers: (i) Bus coupler & transformer bay (ii) Feeder bay. 132 kV equipment interconnection 11.1 GENERAL INSTRUCTIONS: Care shall be taken during sagging operations so that no damage or deformation is caused to the structures.CHAPTER .2 1. 33 kV Main Bus 13. 11 kV equipment interconnection. Bus Bar and Jumper Material 114.0 1. 4. 8. 400 kV Main Bus 2. The ends of the cut piece of conductor / earth wire shall be tied with at least two rounds of binding wire so that the strands do not open out. 33 kV Auxiliary Bus 14. 12. 1.3 2. 132 kV Auxiliary Bus 10. 220 kV equipment interconnection 7. The tying of the binding wire shall be done such that the binding wire does not get tightened in the groove of the T – Clamps or the PG (Parallel Groove) – Clamps or the terminal connectors of the equipment. BUS BAR MATERIAL: The bus bar material generally used in 400 kV. Aluminium pipe Twin ACSR Moose Quadruple / Twin ACSR Zebra / Twin AAC Tarantulla ACSR Zebra Twin ACSR Zebra / Single ACSR Zebra Twin ACSR Zebra / Single ACSR Zebra ACSR Zebra ACSR Panther ACSR Zebra / ACSR Panther ACSR Panther ACSR Zebra ACSR Zebra 1. Cut lengths of conductor and earth wire which are available as surplus / left over material from line works should preferably be used for stringing of bus bars & earth wire. 33 kV equipment interconnection. 11 kV Auxiliary Bus 17.0 2. 220 kV Main Bus 5. 132 kV Main Bus 9.3 BUS BAR & EARTH WIRE 1. overhead bus and droppers: (i) Transformer bay (ii) Bus coupler (iii) Feeder bay.2 mm dia. 220 kV & 132 kV substations is given below: Sl.1 ACSR Zebra ACSR Panther Twin ACSR Zebra ACSR Zebra Twin ACSR Zebra / Single ACSR Zebra ACSR Zebra ACSR Panther Last Updated : 31-1-2008 . Cut lengths of conductor and earth wire left after stringing of bus bars and earth wire can be used for jumpering work. 400 kV equipment interconnection 3.

5 + 3. When the conductor is to be taken from drums. 3. 3. the conductor shall be fixed and tightened in the clamp of the tension hardware on one side of the bus. cm.3 The disc insulators shall be assembled on the ground to form the suspension and tension strings as given below.2 D× F Sq. 3. 5.4 Suspension String Tension String E&M E&M Nos.48 Construction Manual for Sub Stations 3. The suspension and tension hardware shall be assembled as per their respective drawings and the disc insulator string shall be fitted in the requisite portion of the hardware assembly.0 + D× F Sq. Sagging arrangement shall be made on the other end of the bus and the conductor shall be tensioned. Strength (kN) Strength (kN) 400 kV (Anti – fog type) 25 120 2 × 25 120 220 kV at 400 kV GSS (Anti–fog type) 15 70 2 × 15 70 220 kV 13 70 14 120 132 kV 9 45 10 120 33 kV 3 45 4 120 11 kV 3 45 4 120 System Voltage After assembly of the strings.5 3. etc. The conductor shall be cut to the marked length after deducting the length of the tension hardware with insulators and fixed on the clamps of the tension hardware. the complete hardware assembly with the conductor shall be hoisted up and fixed on the beam at this end. 3. the mouth of the W – clips / R – clips shall be widened to prevent any inadvertent removal during service. cm. D = Diameter of the disc in cm. The conductor along with tension hardware set shall then be again pulled up and connected to the beam. small lengths can be unwound from the drum. The limits of the area of defective glazing are given by the following formulas.1 STRINGING OF CONDUCTOR BUS BARS: The conductor shall be handled with care to prevent scratches on it or damage to the strands of the conductor. 20000 b) Total Glaze Defect = 1. Disc insulators shall be cleaned and examined for any cracks / chipping. Disc insulators having any hair cracks or chipping or defective glazing or any other defect shall not be used. Thereafter. the conductor drum shall be placed on a turn table or jacked up on a suitable size of steel shaft. Nos. F = Creepage distance in cm. 2. 2000 where. a) Single Glaze Defect = 0. 4. Measurement of length of conductor required for the bus shall be made thereafter and the conductor shall be released so that it returns to the ground. For longer lengths.0 3.7 Last Updated : 31-1-2008 . Sl. 1. For stringing of bus bars.6 3. 6. The conductor shall be paid out in a manner so that there are no scratches or damages caused to the conductor due to rubbing on the sides of the drum. No.

2 4. the suspension hardware set along with disc insulators shall first be hoisted and fitted on the beam. The spacers shall be fitted on the twin and quadruple conductor bus bars at the spacing shown in the drawing..1. i. 3. JUMPERING OF BUS BARS: For jumpering of different sections of bus bars on the beam.4.3 4. the spacers shall also be fitted at a suitable spacing on the jumpers in order to maintain their shape. the jumper conductor(s) shall be first connected to the bus bar conductor(s) using T – Clamp / Spacer T – Clamp which is suitable for clamping the respective conductors.4 4.1 4.1 4.0 4.9 4.8 Equalizing of tension in the different sub – conductors of the same phase and in the different phases shall be done. The jumpering between equipment shall be done with single / twin / quadruple conductors as per the terminal connectors provided on the equipment.2 4.4. JUMPERING OF CONDUCTORS: The jumpers connecting different sections of the bus bars as well as those connecting equipment to bus bars shall be of Y – type. In case of jumpers for twin and quadruple conductors.e. 4. A typical diagram of Y – type jumpering is given below. if required. bus bar conductor(s) and the jumper conductor(s).2 Last Updated : 31-1-2008 . G. the bus bar conductor(s) shall be again connected with the jumper conductor(s) using properly curved & shaped Y – conductor(s) and 2 nos.1. Spacers are not used at jumper points in case T – Spacers are used for taking jumpers from multi conductor bus bars. PG – clamps as shown in the diagram above. Conductor of approximately the length required for the jumper shall be cut and straightened so that kinks are removed. to ensure equal sag of all the sub – conductors or between phases of the bus section as well as that of adjacent or parallel sections.1. The spacers shall also be provided at points where jumpers are taken from the bus bar using T – clamps and / or P. Thereafter.3 For making Y – type jumpers.Bus Bar & Earth Wire 49 3. clamps. This shall be connected to the bus bar conductor on one side of the beam after taking into consideration the natural curve of the conductor.

6 4.5. 4. The length of the conductor used and its natural curve should be such that a neat and proper curve is obtained in the jumper without any kinks or bends.4 Last Updated : 31-1-2008 . The shield / earth wire shall be paid out in a manner so that there are no scratches or damages caused to the shield / earth wire due to rubbing on the sides of the drum. JUMPERING BETWEEN EQUIPMENTS: The distance between terminal connector of one equipment and terminal connector of other equipment is first measured.3 5. The tension hardware shall be assembled as per the relevant drawings. The clamps of the suspension hardware shall be tightened thereafter.5.1 4. Vertically supported insulators of equipments and Post Insulators should be checked for verticality again after jumpering on both sides. the wire drum shall be placed on a turn table or jacked up on a suitable size of steel shaft.0 5. After cutting the conductor to the required length. if required.5 4.5 4. The clamp of the suspension hardware shall then be tightened after ensuring proportional lengths of the conductor on both the sides of the beam.3 4.6. it shall be connected to the equipment / pipe bus.1 4. When the shield / earth wire is to be taken from drums.2 4. STRINGING OF SHIELD / EARTH WIRE: Sub Station is shielded against direct lightning strokes by overhead shield wire / earth wire. For longer lengths. small lengths can be unwound from the drum. The other end of the conductor shall then be taken up to the bus bar conductor on the other side and measurement of the length shall be taken.1 5. Generally. the suspension hardware along with disc insulators is first fitted on the beam. The earth wire shall be strung from one peak to another peak of the structures as per layout of the GSS. The jumper conductor shall then be connected to the terminal connectors of both the equipments and straightened or shaped as per site condition to give a neat and proper look. In case the jumper is to be connected to equipment / pipe bus near or under a beam.6.2 5. The appropriate length of the conductor shall be cut and then straightened so that curves and kinks are removed. The conductor shall be passed through the clamp of the suspension hardware. The end of the conductor shall be taken up to the terminal connector of the equipment / connector fitted on the pipe bus.2 4. The measurement of length of the conductor up to the equipment / pipe bus shall be made.3 5.3 This shall then be passed through the clamps on the suspension hardware so that the proper curve is obtained.4.4 4. The methodology followed for system up to 400 kV is by suitable placement of earth wire so as to provide coverage to all the station equipment.50 Construction Manual for Sub Stations 4.6.5. and corrected.5. an angle of shield of 60° for zones covered by two or more wires and 45° for single wire is considered adequate. JUMPERING FROM BUS BAR TO EQUIPMENT / PIPE BUS: Approximate length of the conductor required for the jumper shall be cut and then connected to the bus bar conductor. The conductor shall be cut to the appropriate length and then connected to the bus bar conductor on the other side. The shield / earth wire shall be handled with care to prevent scratches on it or damage to the strands of the wire.5.

to ensure equal sag of all the earth wires in adjacent or parallel sections. The earth bond provided with the earth wire tension clamp shall be connected to the specified point on the peak of the structure and to the earthing riser.2 Last Updated : 31-1-2008 .0 6. These shall be connected together using a PG –Clamp. if required. which is used as a down conductor from the peak.7 6. Thereafter. Measurement of length of shield / earth wire required shall be made thereafter and the shield / earth wire shall again be released so that it is returned to the ground. the complete hardware assembly along with the shield / earth wire shall be hoisted up and fixed on the peak of the structure at one end. Adjustment of tension in the earth wire may be done. if required.6 5.1 6.5 The shield / earth wire shall be fitted and tightened in the clamp of the tension hardware on one side.Bus Bar & Earth Wire 51 5. for the purpose of connecting the shield / earth wire to the earth mesh of the sub station. The shield / earth wire along with tension hardware set shall then be pulled up again and connected to the peak of the structure. The shield / earth wire shall be cut to the marked length after adding the length of the wire required for jumpering and fitted in the clamp of the tension hardware at the marked point. Sagging arrangement shall be made on the other end and the shield / earth wire shall be tensioned. so that these lengths when joined together form a smooth and proper curve. JUMPERING OF SHIELD / EARTH WIRE: The lengths of the earth wire which remain outside the tension hardware on the peak of the structures shall be cut. 5.

52 Construction Manual for Sub Stations Last Updated : 31-1-2008 .

CHAPTER - 4

ALUMINIUM PIPE BUS BAR AND JOINTS
1.0 1.1 ERECTION OF ALUMINIUM PIPE BUS BAR: Aluminium pipes are used for 400 kV and 33 kV bus bar jumpers and interconnections at 400 kV GSS. The diameter of the pipes is 114.30 mm and 73.03 mm for 400 kV and 33 kV respectively. The height of the 400 kV main bus is 8 meters & 10 meters and that of jumpers is generally 8 meters, 10 meters & 13 meters. Fixed, sliding and expansion type clamps are fitted on the already erected post insulators as per the drawing. The standard length of aluminium pipes is generally 6.0 to 7.0 meters. To reduce welding work at the bus height in case longer lengths are required, a maximum of 4 to 5 lengths of aluminium pipes may be welded together on the ground using straight run couplers. The pipe length is then lifted and erected on the post insulators. If required for the bus length, the already erected pipe lengths are welded together at the bus height. In case the bus height changes, then the pipes at the different levels are welded together with a piece of pipe using appropriate angular couplers (90° or 110° or 135°) as per drawing. JUMPERING OF ALUMINIUM PIPES: Jumpers between equipment to equipment and equipment to bus may either be direct or supported on post insulators. In cases where the length required for jumpers is more than one pipe length and where angles are required to be given in the jumpers, welding of aluminium pipe to pipe or pipe to angular connectors is got done. Such welding may also be required to be got done after erection / fitting of pipes on clamps / connectors. For jumpering between equipments, the pipes are erected between the equipments, supported & fitted on the clamps on the post insulators where provided, and fitted on the terminal connectors of the equipments. For jumpering between equipment and bus, the pipes are erected between the equipment and the bus, supported & fitted on the clamps on the post insulators where provided. One end is fitted on the terminal connectors of the equipment. The other end is then welded to aluminium pipe using appropriate angular connector(s) (20° or 80° or 90°) as per drawing. All the open ends of pipes are closed with corona end shields. JOINTING OF ALUMINIUM PIPES / COUPLERS / CONNECTORS: The joints / couplers shall be got machined in order to perfectly match their inner / outer diameter with the aluminium pipe. All the surfaces to be welded must be thoroughly cleaned with Acetone or Alcohol to remove any oxide layer and foreign contaminants present on it to attain a fast joint and avoid porosity. In addition, a stainless steel wire brush shall be used for cleaning the surfaces.

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Straight Run Coupler: Before fitting the straight run coupler, the edges of the pipes to be welded for straight joints are to be beveled at an angle of 45° with a flat file to make a V – groove at the ends of joint. In cases where outer diameter of sleeve does not match the inner diameter of pipe, the sleeve shall be got turned to match the inner diameter of the pipe. The straight run coupler is then to be pressed and both the pipes are pushed on to it till their ends come near the centre of the coupler. The centering pin of the coupler is fitted in the hole provided for it and the pipe ends are brought together until they touch the centering pin. The straight run coupler is then split open so that it fits tightly on the inner surface of the pipe. It is held in this position till at least 25% of the welding of the coupler has been done. The welding of the joint is then done till the V – groove between the pipes is filled with the fused metal. Angular Coupler: For jointing of pipes with angular coupler, the ends of both the pipes are fitted into the coupler. The pipes are then welded on the coupler. Angular Connector: For jointing of pipe with angular connector, the end of the pipe is first fitted into the connector and welded. The connector with the pipe is then fixed on the pipe bus and the connector is welded to the pipe bus. ALUMINIUM WELDING: The following material / T&P / consumables are required for carrying out the work of welding of aluminium pipes / couplers / connectors. a) T.I.G. / M.I.G. welding set with Tungsten wire. b) Argon Gas. c) Oxy – acetylene torch with accessories or blow lamp. d) Filler wire. e) Water tank for welding. f) Tools such as chipping hammer, files, sand paper, steel wire brush, wind screen, blue glass slits, hacksaw frame, blades, power saw, etc. g) Cleaner, dye and developer. h) All safety equipments. T.I.G (TUNGSTEN INERT GAS) welding utilizes high frequency A.C. generating set and welding torch having tungsten wire with outflow of inert gas like Argon, etc. M.I.G. (METAL INERT GAS) welding process is used as an alternative when T.I.G. welding is not available. To avoid cracks in the joints after welding, the surface should be preheated uniformly with oxy – acetylene torch or blow lamp. During welding, continuous flow of inert gas shall be maintained over the joint as well as inside the pipe to avoid oxidation on the inside surface. This flow of inert gas on joint should continue for at least 15 seconds after the welding of joint is completed.

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All the welding at a joint must be in one layer. If more layers are required at the joint, every bottom layer shall be cleaned with wire brush and checked for cracks before starting welding of the second layer. If any crack is observed, the whole layer shall be chipped off and refilled. The joint, when completed, must be filed smooth with a wood file and fine sand paper. Wind shield shall be used, if required, for protecting the joints from the blowing wind which may take away heat and inert gas flow at the surface of joints. Every care shall be taken for preventing the scratches and roughness on the aluminum surface. The welding should be got done so that molten mass is filled in gaps and no cracks or imperfections are present in joints. Unacceptable joints shall be chipped off for re – welding. Each and every joint shall be subjected to: a) Physical examination. b) Liquid penetration test. For liquid penetration test, the following three items are required: a) Cleaner for cleaning the joint. b) Red dye for spraying on the cleaned joint which will penetrate into the cracks, if any. c) White developer to be sprayed on the joint that will draw the red dye from the cracks and make these cracks visible, if present. Depending upon the site conditions, some welding can be got done at ground level and the rest is to be done at a height of 8.0 to 13.0 meters from the ground level as per requirement. The necessary arrangements for welding of joints at such heights shall be made.

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56 Construction Manual for Sub Stations Last Updated : 31-1-2008 .

G. The transformer tank should not be opened when it is raining.1 GENERAL INSTRUCTIONS: The erection work shall be got done generally as per instructions / procedures prescribed in the following documents: a) b) c) d) Manufacturer’s Erection & Installation Manual. oil flow indicators.0 1. it should be maintained by filling in gas from the cylinder on the transformer. Oil surge relays.CHAPTER – 5 POWER TRANSFORMERS 1. Check the open and closed conditions of contacts provided in equipment such as M. pipe work and A – frame can be stored under covered sheds. IS: 10028 (Part II) – 1981: Indian Standard Code of Practice for Selection. A positive pressure (generally 0. However.L. 1. In case of reduction in pressure. Manufacturer’s Erection Drawings.6 1.5 1. Transformer oil drums should not be stored in low lying areas.. etc.4 All the accessories should generally be stored in a closed shed / room. 1) issued by the Central Board of Irrigation & Power. Installation and Maintenance of Transformers: Installation. radiators. 1. They should be stored so that the air release hole (smaller hole) is on the upper side and at an angle of 45° to the vertical as shown in the diagram below. conservator.8 Last Updated : 31-1-2008 .3 1. 1. The core and winding should be exposed to the atmospheric air for the minimum possible time period and for not more than 8 hours at a time. before they are installed.15 kg / cm2 at 30° C) should always be maintained. The weather conditions during transformer erection should be dry. The Bushing CT’s fitted in the turrets should be got tested by the protection wing before erection of turrets. accessories such as condenser bushings.2 The work shall be carried out under the supervision of Work – In – Charge/ Manufacturer’s Engineer and as per instructions given by him / them.O. Buchholz relays.7 1. headers. The gas pressure in transformers received gas filled should be checked periodically. Transformer Manual (Technical Report No.

2 2.2.4.00 torr (maximum) is to be applied for at least 12 hours for transformers of up to 145 kV class and 24 hours for transformers of higher voltage class.1 2. Initial oil filling in Transformers received gas filled: Oil Preparation: The oil supplied in oil drums (for first filling.2 2.1 2. and for erection if required.3.2. The extent of vacuum and the time duration of its application shall be as per Manufacturer's recommendations. The vacuum in the tank is then slowly released by slightly opening the valve on which the breather is connected so that only moisture free air goes inside the tank. 2. the oil is refilled after the day’s erection activities are completed. Internal Inspection: Internal inspection of transformers up to 145 kV class may be carried out if recommended by the manufacturer and as per procedure prescribed by him.3.1 The oil temperature thermostat in the filter machine should be set at 60°C.4 2.2.2 Last Updated : 31-1-2008 . The oil level can be seen in the transparent plastic pipe provided. topping up & OLTC) is first filled into oil storage tank(s) through filter machine.2 2.4. Apply vacuum to the transformer. The vacuum pipe is generally connected to the pipeline between transformer tank and conservator.2. Oil Filling: The treated oil shall then be filled into the transformer tank under vacuum until the oil level reaches 250 mm below the top cover level. IR values should not be measured when the transformer tank is under vacuum.10 2.1. Connect a transparent plastic pipe (either reinforced or having wall thickness of 5 to 8 mm suitable for withstanding vacuum) between the top and bottom valves of the transformer to check the oil level. Erection of the part of the pipeline between the tank and the conservator up to the Buchholz relay.1 2.2. Connect a breather to any valve above the tank oil level through a suitable pipe.2 2.4 2. The oil is drained from the tank for internal inspection.1 2.1. Vacuuming of the Transformer: Provide equalizing connections between main tank and OLTC Diverter Switch chamber(s) and isolate those parts of the Transformer which are not designed for vacuum.3 2.3 2. In case this is not specified by the Manufacturer.0 2.9 The top oil temperature should invariably be noted during measurement of IR values of transformer. This oil is then filtered in the tank(s). The following oil values shall be attained so as to facilitate early and effective dehydration of transformer: a) b) Break Down Voltage: Moisture Content: 70 kV (Minimum) 10 ppm (Maximum) 1.58 Construction Manual for Sub Stations 1.5 2. The rate of release of vacuum should be kept very slow so that the silica gel in the breather does not get sucked into the tank. Where connections are required to be made inside the tank and when the erection work is to be continued on the next day. then vacuum of 1.

1. Assembly and fitting of equalizing pipeline between tank cover. 4. when supplied separately. as required. 3.7 6. fitting of valves. inspection covers. Erection of Accessories: Erection of main conservator & On Load Tap Changer (OLTC) conservator along with their supports. The arrow marks on the oil pumps and oil flow indicators should point towards the transformer tank.3 4. as per General Arrangement (GA) drawing. if provided. etc.0 The oil received in drums (for topping up & OLTC) for transformers received oil filled is filled into a storage tank through filter machine. Pumps. if provided.2 are attained. levelling and centering of cooler bank supports (A – frame). LV and TV turrets. if not of blue colour).2 6. Erection of HV. Ensure that diaphragms are fitted on both ends of the vent pipe.2 4.0 4. as provided. expansion joints.8 Last Updated : 31-1-2008 .3 6.6 5.1 4. Erection of Explosion Vent.4 4. Assembly and fitting of pipelines for breathers of main and OLTC conservators and fixing of breathers after checking the silica gel (to be replaced / regenerated. The arrow marks on the Buchholz relays should point towards the conservator. Placing on foundation. Erection of lower and upper headers on the A – frame. etc. Erection of radiators on headers / tank.5 6. Assembly and fitting of Buchholz pipeline. Fitting of Pressure Relief Devices along with pipes.4 6. turrets. expansion joints as provided and Buchholz relays.6 6. This oil is filtered in the tank until the values given at para 2. Non Return Valves. Grouting of cooler bank supports (A – frame). Assembly and fitting of upper and lower cooler pipe line from transformer tank to respective headers including fixing of Valves. oil flow indicators.2 6. TV & neutral bushing(s) and making their connections inside the tank.1 6. Erection of HV. the relay near the tank is designated as Buchholz Relay – I and the relay near the conservator as Buchholz Relay – II. LV.1 5.0 6. Where two Buchholz relays are provided. if provided.0 5. Transformers with tank mounted cooler bank / radiators: Erection of headers.Power Transformers 59 Additional precautions prescribed by the Manufacturer for dry air and human safety during such erection activities should be followed. Erection of Radiators on the headers.5 4.. Transformers with separately mounted cooler banks: Large size EHV Transformer (generally 245 kV class and above) are provided with separately mounted cooler banks. and connecting it to the equalizing pipeline and the main conservator.

The levelling. In such a case. Allow the transformer to cool down to atmospheric temperature. During this process. The dehydration process is thereafter continued for a minimum of another 24 hours or until the oil values given at para 8. centered and then grouted.7 are attained. oil is drawn from the bottom of transformer into the filteration plant and let into transformer again at the top for removing any settled moisture / impurities.10 6. A typical indicative drying out curve is shown below: 6. i. Ensure that the sealing provided on the air passage of the breathers has been removed.60 Construction Manual for Sub Stations and also filling of oil in the oil cup. the air release valves / plugs provided on the top of the conservator should be kept open. The readings of IR values shall not be taken during this process since these will be misleading due to erroneous indication of winding temperature. if provided.0 8.1 8. centering and grouting of ground mounted supports is to be got done before erection.9 Assembly and fitting of pipeline for the OLTC Diverter Switch including valves and oil surge relay and connecting it to the OLTC conservator. In the beginning. In case these are ground mounted.4 8. The test voltage of 5 kV is applied for one minute.e. 6. Measure the IR values at 2 hour intervals during the cooling period. measure insulation resistance values of the transformer every 2 hours.5 8. Dehydration of Transformer by Hot Oil Circulation: When starting the dehydration.0 8. If there is moisture in the windings. the cycle is reversed.2 8. Erection / placing of fan control cubicle / marshalling box & OLTC drive mechanism. then the dehydration at constant temperature is carried out for a minimum of 72 hours or until the oil values given at para 8.3 8.7 are attained.11 7. These reach a constant value after the drying out is complete. The moisture in the oil is continuously removed by the filteration plant. oil is drawn from the top and fed at the bottom. The arrow marks on the oil surge relays should point towards the conservator. IR values can be plotted against time. After about 8 – 12 hours of circulation in this manner. then these are to be placed on the foundation. levelled.6 Last Updated : 31-1-2008 . After the moisture has been removed from the winding. Filling of topping up oil in the transformer tank and conservator. the IR values at constant temperature will drop down as the moisture is removed from the insulation and gets dissolved in the oil. the IR values drop down as the temperature increases. then the IR values at constant temperature will remain the same. the IR values will start rising as the dissolved moisture in the oil is removed. If no such time is prescribed. If there is no moisture in the windings. Assembly & fitting of cooler fans. including fitting of supports.. The winding temperature is assumed to be the same as top oil temperature under steady state conditions. the dehydration is stopped after the time prescribed by the manufacturer. then. The oil shall be filled up to 1/3rd level in the conservator. During dehydration.

295) and in the IS : 10028 (Part – II) – 1981.10 8. 8. then carry out further drying out by adopting any of the following processes. a) b) c) d) Hot air circulation.Power Transformers 61 8. Last Updated : 31-1-2008 . the insulation resistance changes by a ratio generally in the range of 2:1 to 1. the transformer can be charged.1 Drying by Hot oil circulation and vacuum pulling: Carry out hot oil circulation on the transformer.8 Compare the insulation resistance values with the following reference values: i) ii) New transformers: Old transformers: Factory Test Results. the hot oil circulation is continued for 2 – 3 volumes of the transformer oil. vacuum pulling and Nitrogen filling. Hot oil circulation and short circuit heating. Hot oil circulation and vacuum pulling. as convenient.9 If the specified IR values are not attained. Previous Test Results. Insulation resistance varies inversely with the temperature. 8. The processes at (a). However.7 The following oil values shall be attained in order to increase the time interval before re filteration of oil is required when the transformer is in service: a) b) Break Down Voltage: Moisture Content: 80 kV (Minimum) 10 ppm (Maximum) 8. If the specified IR values are achieved.9 below. the manufacturer is to be contacted. The process at (d) is mostly adopted and is described at para 8. For a 10°C change of temperature.10. The IR values and the temperature are noted.4:1. Heating. (b) and (c) are described in the CBIP Manual on Transformers (Publication no. in case of transformers within guarantee period. After maximum top oil temperature is attained.

10.10. Pressurizing of air cell in the main conservator: Method recommended by the Manufacturer: Open the air release plugs / valves provided on the top of the conservator. Drain the oil from the transformer through the bottom filter valve till the conservator is empty.11 9. then another cycle of the above process as given at para 8.1 9.10.1.6 8. otherwise it is continued till two consecutive readings are same.2. Start hot oil circulation and continue for 2 – 3 volumes of the transformer oil after maximum top oil temperature is attained.10.4 Last Updated : 31-1-2008 .10.1) as well as for allowing dry air into the transformer while draining oil (para 2. then the drying out process is stopped.4 8. for application of vacuum (para 2. These are compared with the reference values.2 9. If there is no change in the IR values as measured above at para 8. After constant IR values are achieved. Inject air into the Air Bag / PRONAL through the air filling device to a maximum pressure of 0.1 & para 8. The IR values as measured above at para 8.0 9.1 & para 8. 8.10. 9. which is provided with a pressure gauge and a filling pipe in which a non return valve is fitted.10.3 are compared.1 kg / cm².2 & para 8. If there is improvement in the IR values. If the previous IR values are achieved.3 is continued till two consecutive readings are same.10.10.5) are to be followed.3 Remove the breather. then the above process as given at para 8. If still there is no change. the drying out process is stopped and the transformer is allowed to cool down to atmospheric temperature. Connect the air filling device. Any valves in the breather pipe should be kept open.10.3.10.1. as given earlier.62 Construction Manual for Sub Stations 8.1 9. the transformer can be charged. Fill the oil again into the transformer.10.10. This can be checked by ensuring that there is no oil in the Buchholz relay(s).3 is carried out. The IR values are then measured and the temperature is noted.3 8. The precautions.2 & para 8. to the breather pipe. The IR values and the temperature are noted.1.1.2 Drain the oil from the tank and apply vacuum immediately and maintain for 12 hours.5 8.2.

Connect the air filling device.2.9 9.1 10. When all the air has been expelled.1 / para 3. Oil mixed with air bubbles shall start coming out.1.8 9. Filling of oil in OLTC and its Dehydration: Fill filtered oil (as per para 2.1 kg / cm².Power Transformers 63 9. Refit the breather on the pipeline.1. Remove the breather. to the breather pipe. Where air release plugs are provided. they should be fitted but not fully tightened.1 9. Refit the breather on the pipeline.3 9.2. Carry out dehydration of the oil. This oil is filtered in the OLTC diverter switch chamber(s) until the values given at para 8.1. Release the air pressure thereafter.1.9 10. The prismatic oil level gauge. Continue the oil filling.2 9.2. oil along with air bubbles starts coming out of the air release plugs / valves. Temporarily stop the oil filling operation when oil along with air bubbles starts coming out of the air release plugs / valves.2.2.7 9. Close the air release plugs / valves while still maintaining the air pressure. if provided on the conservator. Open the air release plugs / valves provided on the top of the conservator. Close the air release valve such that the flow of oil will be very slow.8 9.5 9.1.2. Continue the oil filling in the transformer till the level shown on the Magnetic Oil Level Gauge (MOLG) corresponds to the oil temperature as per the reference mark given on the MOLG. Stop the oil filling after ensuring that no air bubbles come out with the oil.4 9. which is provided with a pressure gauge and a filling pipe in which a non return valve is fitted. 9.2. The level of oil shown on the Magnetic Oil Level Gauge (MOLG) is checked with respect to the oil temperature and the reference mark given on the MOLG.0) in the OLTC diverter switch chamber(s) and the OLTC conservator.2.1. Inject air into the Air Bag / PRONAL through the air filling device to a maximum pressure of 0.1.6 9.2 Last Updated : 31-1-2008 .7 are attained.5 Slowly pump the oil through the bottom filter valve. only oil will come out through the air release plugs / valves. Any valves in the breather pipe should be kept open. Alternate Method / Field Practice: Keep the oil level in the conservator at approximately 1/3rd level. The oil is allowed to come out until there are no air bubbles in the oil.10 9.2. When all the air has been expelled. Release the air pressure thereafter.0 10.6 9. The prismatic oil level gauge provided on the conservator will indicate full oil level. The air in the conservator outside the Air Bag / PRONAL is pushed out through the air release plugs / valves. The air release plugs / valves are then closed while still maintaining the air pressure. will indicate full oil level.2 9.7 9.

Prepare the cables at both the ends and fit into cable glands. a) Air release plugs provided on the Main tank cover and bushing turrets. etc.0 11. Fix / fit minor accessories as below: a) b) c) d) e) f) Clamps / Brackets for pipes and fixing of pipes on them. f) Air release screws on through oil type Bushings (up to 33 kV). if provided. Protective covers for OLTC operating shaft(s).2 13. Synchronize the operation of all the three OLTC diverter switches so that all the three phases operate almost simultaneously. Condenser type Bushings i) On Load Tap Changer / Diverter Switch Chamber. as provided.0 15.1 12. Fitting of terminal connectors on the bushings. e) Pressure relief device (PRD) and Explosion Vent (if provided).1 13.0 13. protective relays. ensure that the tap position indicated in the OLTC drive mechanism and at the head of OLTC diverter switch(es) are the same.0 After installation work is over.2 12. Fixing of cable trays / brackets on the tank cover and clamping of cables on them. Any other accessories.3 13. P. the transformer is to be made ready for commissioning.4 14. Drill holes in the cable gland plates of the fan control cubicle / marshalling box / Temperature meter box as per requirement. Problems arising out of peculiar situations are to be assessed and solved on case to case basis. Last Updated : 31-1-2008 . b) Air release plugs provided on the Radiators. I. The checks / tests given hereafter are generally applicable.0 12. Prior to putting the transformer into service.3 13. Headers and Cooler Bank pipelines. Lock the bolts & nuts of the coupling brackets of the operating shaft(s).64 Construction Manual for Sub Stations 11. P. d) Float type Oil Surge Relays (OSR). Check the operation of the OLTC manually and make adjustments so that there are equal numbers of free turns of the operating handle after each tap change in the diverter switch both during Raise & Lower operations. Fix the cables on these cable gland plates and connect the wires as per schematic drawing. h) Upper terminal of O. Cabling on the Transformer: Carry out laying of control cables from fans. etc.1 Air Release from the Transformer: Release air from the following air release points till there are no air bubbles in the oil coming out from these air release points. c) Buchholz Relays. to the fan control cubicle / marshalling box / Temperature meter box. Specific checks / tests prescribed by the manufacturer are also to be carried out. bushing / WTI CT’s. g) Air release screws / plugs if provided on the mounting flange of O. I. 12. When connecting the operating shaft(s). gear boxes and operating shafts between OLTC drive mechanism and OLTC diverter switches. Condenser type Bushings. Fitting of sensors / probes for oil & winding temperature indicators after filling oil in the pockets provided for them. attention should be paid to the checks and tests given in the following paras. Assembly of OLTC Drive Mechanism & Operating System: Fix the brackets.

Arrow on the oil flow indicators and the oil pumps is pointing towards the transformer tank. Inspect the transformer all over and check all flanged joints and fittings for oil leakages. Trip and Cooler control in the Oil and Winding Temperature Indicators. Setting of all the mercury switches for Alarm. The colour of silica gel in the breathers is blue and that oil is filled up to correct oil level mark in the oil cup.10 16.6 16. Isolating valves in Buchholz pipe line and all the radiators and any valve if provided in the breather pipeline are fully opened and locked in the open position. the settings are made as given below: a) Oil Temperature Indicator (OTI): Alarm: Trip: ON: OFF: ON: OFF: Start: Stop: Start: Stop: ON: OFF: ON: OFF: 70°C 60°C 80°C 70°C 55°C 50°C 65°C 60°C 80°C 70°C 90°C 80°C 16.7 16. OTI. etc. Release air from the inside of the transformer tank by opening all plugs / venting screws / valves on radiators. oil flow indicators.Power Transformers 65 16.11 16.12 16. OLTC oil surge relay (float type) and gas collection pipe. If found necessary. bushings. Buchholz relay contacts are not locked and these are in ‘SERVICE’ position.1 PRE – COMMISSIONING CHECKS: All equipments are mounted in position as per General Arrangement drawing of the manufacturer. The thermometer pockets provided for oil and winding temperature indicators are filled with oil. WTI.2 16. Oil level in the condenser bushings. and tank cover until oil appears. Close these after the above check has been carried out.3 16.0 16.13 16. re – tighten the bolts. As per general prevailing practice. Arrow on the Buchholz Relays & Oil Surge Relays is pointing towards the Conservator. if provided. The transport locks provided in equipment such as the MOLG.5 16.14 b) Winding Temperature Indicator (WTI): Fan / Fan Group – I: Oil Pump / Fan Group – II: Alarm: Trip: Last Updated : 31-1-2008 .4 16.8 16. have been removed. Minimum clearances between live parts and between live parts to earth are as per General Arrangement drawing. Buchholz relay. Oil level in the main conservator and OLTC conservator is as per the oil temperature.9 16.

20 16. Jumpering arrangement to achieve phase matching. temperature meter box. if the transformer is to run in parallel with another transformer. OLTC Surge Relay (U. Restricted Earth Fault (REF). as provided). Oil temperature high alarm. cooler bank. Bolts & nuts of the coupling brackets of the operating shaft(s) of the OLTC have been locked. Buchholz Trip (I & II) by draining oil from the relay. Air cell fail alarm.15 The Transformer neutral is connected to earth at two separate earth pits / electrodes which in turn are connected to the earth mat. Setting of overload / protection relays / MCBs for fans & pumps and for OLTC motor as per their rating. etc. 17. Neutral Displacement alarm. Winding temperature high alarm (LV). Earth fault. Master Trip relays and alarm annunciation on actual operation of the transformer mounted protective Relays and supervisory equipments. V. i) ii) iii) iv) v) vi) vii) viii) Buchholz Alarm (I & II) by draining oil from the relay.1 PRE – COMMISSIONING TESTS: Non Trip Alarms: Operation of the corresponding auxiliary relays if provided and alarm annunciation on actual operation of the transformer mounted protective Relays and supervisory equipments. Over flux. Circulating Current Differential Last Updated : 31-1-2008 . Oil Temperature Trip. The Transformer tank. Winding Temperature Trip (TV). Winding Temperature Trip (LV). if provided.3 Testing by the Protection Wing of Over current.21 17. OLTC Conservator Low oil level alarm.2 Trip Alarms: Operation of the corresponding auxiliary relays. Winding temperature high alarm (TV). 17.66 Construction Manual for Sub Stations If the site and load conditions warrant. i) ii) iii) iv) v) vi) vii) Main Conservator Low oil level alarm. W / common. cooler control cabinet.19 16. Winding temperature high alarm (HV). Proper connections and tightness of terminal connectors provided on Bushings. higher settings of the winding temperature alarm & trip contacts may be adopted for which the manufacturer’s recommendations are to be followed. 16.17 16. Winding Temperature Trip (HV). No oil is visible in Explosion Vent sight glass.18 16. OLTC drive mechanism.0 17. Pressure Relief Device.16 16. marshalling box. 16. as provided are earthed.

i..C. as provided. b) c) d) e) f) Last Updated : 31-1-2008 . “Pump Fail: Group – 1 & 2”.11 c) d) e) 17.. 17. Check functioning of operation counter.C. supply to the Cooler Control Cubicle (CCC) / Fan Control Cubicle (FCC) / Marshalling Box. Confirm functioning of mechanical locking at extreme tap positions. Verify the reading of Tap Position Indicator (TPI) on Remote Tap Changer Control (RTCC) panel on all the tap positions. Direction of rotation of fans and pumps.. Observe any abnormal sound during this operation. Manual operation of OLTC: a) b) Operate by handle from tap no.7 17. alarm annunciations. 1 to the maximum tap position & back to tap no. Confirm functioning of electrical limit switches at extreme tap positions. as provided in the RTCC Panel. Operation of fans / oil pumps as per settings made in the winding temperature indicators as per para 16. Testing of alarm annunciations.6 17.14. Lamp indications on RTCC Panel for fans and pumps. Check phase sequence of the A. “Stand by Fan Fail: Group – 1 & 2”. associated Master Trip relays. Phase sequence of the A. This may be checked for operation of each Master Trip Relay for 2 or 3 protective relays. etc. 1 to the maximum tap position & back to tap no.5 17. etc. 17. such as “Fan Fail: Group – 1 & 2”.4 Tripping of HV circuit breaker & inter tripping of LV circuit breaker on operation of Master Trip Relays.e.8 17. Check tripping of MCB in OLTC Drive mechanism by pressing “Emergency Push Button” from local and from RTCC Panel. “Stand by Pump Fail: Group – 1 & 2”. supply to the OLTC drive mechanism.Power Transformers 67 protection. 1.1 from local and from remote. “Cooler Control Supply Fail”. Step by step operation of the OLTC (only one tap should change in one pulse or with continuous pulse). There should be no electrical operation of the OLTC with handle inserted.10 17.9 17. Operate On Load Tap Changer (OLTC) from tap no. Transformer Differential protection relays. Never start this OLTC operation from extreme tap positions. RTCC Panel.12 Electrical operation of OLTC: a) Operation of handle interlock. Operation of stand by fans / pumps on failure of each fan / pump.

Testing of alarm annunciations.. Magnetic balance test on all three phases of LV winding by applying single phase voltage one by one between phase and neutral of one phase and measuring the induced voltage on the other two phases. i) 17. b) Magnetizing current measurement of all three phases of HV winding at Tap no.. 1 to the maximum tap. “OLTC out of Step”.e. Short circuit current measurement of all three phases of HV winding at Tap no. etc. “OLTC Motor MCB Trip”. Magnetic balance test on all three phases of TV winding. provided in the RTCC Panel. in case all the three phases of the TV winding have been brought out. If the transformer is to be run in parallel with another transformer. “OLTC Control Supply Fail”. Checking of continuity of contacts in diverter switch: During short circuit current measurement test above. i. For star connected TV winding. the voltage is applied one by one between phases of the TV winding keeping HV & LV windings open. such as “Tap Changer Stuck / Tap Change Delayed”.14 c) d) e) f) g) h) i) Last Updated : 31-1-2008 . Testing of Transformer: a) Magnetizing current measurement of all three phases of LV winding with single phase supply applied between phase and neutral one by one keeping HV & TV windings open. LV winding is kept open – circuited.68 Construction Manual for Sub Stations g) h) Checking of Lamp Indications provided in the RTCC Panel. LV and TV WTI CT testing by measuring the current in the leads from the WTI CT terminals to the winding temperature indicator(s) during the above short circuit current measurement tests. There should not 17. “Master – Follower Operation of Transformer”. 1 with single phase supply applied between phase and neutral one by one with LV winding short – circuited and TV winding open – circuited. HV. 1 with single phase supply applied between phase and neutral one by one with TV winding short – circuited in case all the three phases of the TV winding have been brought out. 1 with single phase supply applied between phase and neutral one by one keeping LV & TV windings open.13 Reading of Oil & Winding temperatures on Remote Temperature indicators provided in RTCC Panel with reference to the OTI & WTI fitted on the transformer. single phase supply is applied between phase and neutral of TV winding one by one keeping HV & LV windings open. connect an analogue type AVO / multi – meter on the HV winding and operate the OLTC from tap no. In case of delta connected TV winding. Magnetizing current measurement of all three phases of the TV winding in case all the three phases have been brought out. by applying single phase voltage one by one between phase and neutral on one phase (for star connected winding) or between phase to phase (for delta connected winding) and measuring the induced voltage on the other two phases. Short circuit current measurement of all three phases of HV winding at Tap no. operation of OLTC Drive mechanism by making one transformer as ‘Master’ and another one as ‘Follower’ & vice versa.

HV – TV & LV – TV using 5 kV megger. Appearance 2. Resistivity (90ºC) × 1012 (ohm – cm). Min. between HV – Earth. Testing of transformer oil. 6.015 0.5 to 170 > 170 Clear. measurement of Capacitance and Tan δ of condenser bushings and transformer windings for reference. Winding resistance measurement of all three phases of HV (at Tap no.89 0. Oxidation Stability of inhibited oil (i) Induction Period (hours) Similar values as before filling Last Updated : 31-1-2008 . Max.03 10 10 10 0. Dielectric dissipation factor at 90ºC and 40 Hz to 60 Hz.5 72. Max. Transformer Turns ratio measurement between HV – LV.010 6 80 27 140 -6 35 0. Checking of Vector Group of the transformer. Breakdown Voltage (kV). S. Max. and 60 sec.89 0. Max. Subject to availability of testing instrument. Density at 29. Max. 10.4 0. Max. 7. 1. 5.4 0. 11. Min. No. then shorting each LV phase with neutral one by one and measuring open delta voltage and closed delta current.4 0. The top oil temperature is to be recorded. Max. Min. 9. j) In case of tertiary winding where two terminals have been brought out. 13. The top oil temperature is to be recorded.1 6 80 For Reference 27 140 -6 35 0. free from sediments and suspended matter 0. Min. LV and TV windings.1 6 80 27 140 -6 35 0. Neutralization value (mg KOH / g).03 0. Flash Point (ºC). Interfacial Tension (mN / m). The limits for unused mineral oil filled in New Power Transformer as recommended in Table – 1 of the above Indian Standard are given below. Dissolved Gas Analysis Viscosity at 27ºC (cSt). Oxidation Stability of uninhibited oil (i) Neutralization Value (mg KOH / g).89 0. 12. 3. 1).03 0. Insulation resistance measurement (meggering) and recording the readings for 15 sec. The following tests are generally desired to be got carried out on transformer oil as per IS 1866 : 2000 – Code of Practice for Electrical Maintenance and Supervision of Mineral Insulating Oil in Equipment. Water Content (ppm).1 k) l) m) n) o) p) 14. HV – LV. 4. testing of TV winding by giving 3 – phase supply to HV. TV – Earth. (ii) Sludge (percent by mass). The 60 second value shall be taken as the reference value for future comparison.5ºC (g / cm3). Property of Oil Highest Voltage of Equipment (kV) < 72. The top oil temperature is to be recorded.Power Transformers 69 be any break in the current during tap change which is indicated by the sudden deflection in the multi – meter reading. LV – Earth. It is not advisable to carry out this test when the relative humidity is above 75%. Max. 8. Pour point (ºC).015 0. HV – TV & LV – TV using turns ratio measuring instrument.

Breakdown Voltage (kV).5 72. 17. Dielectric dissipation factor at 90ºC and 40 Hz to 60 Hz. Transformer is to be charged at tap no.03 0. Max.5 18. Appearance 2.6 18. Neutralization value (mg KOH / g). 1. 18. Max.3 18.8 19. Recharge the transformer at Tap no. 8.015 0. the “MAINTENANCE MANUAL FOR POWER TRANSFORMERS” of RVPN (erstwhile RSEB) should be followed. r) Density at 29. Dissolved Gas Analysis Other tests as prescribed in the Operation and Maintenance Manual of the Manufacturer.15 18. Min. the operation of the OLTC is to be checked by increasing the tap position upto the tap corresponding to the system voltage. Then take load on the transformer. Max. 7. CHARGING OF TRANSFORMER: Check the tripping of HV circuit breaker & inter tripping of LV circuit breaker on operation of Master Trip Relays.03 0.0 18. Property of Oil Highest Voltage of Equipment (kV) < 72. 3. During this period observe the temperature rise of the oil & winding. 5.7 18.5 to 170 > 170 Clear. Manufacturers recommend that transformer be kept on no load for 24 hours.03 10 10 10 0. For operation and maintenance of Power Transformers.89 0.5ºC (g / cm3).1 The results of all the above tests are to be recorded for future reference. tap position of the transformer is to be fixed according to HV side voltage available. free from sediments and suspended matter 0.70 Construction Manual for Sub Stations q) The following tests as recommended in IS : 1866 are the minimum tests which should be got done on the transformer oil. De – energize the transformer and check the Buchholz relay for any collection of air / gas. Tap position (same voltage ratio) should also match with the transformer already in service in case of parallel operation. 2.015 0.89 0.010 6 80 6 80 For Reference 6 80 S. No. 2 otherwise transformer may trip on differential protection due to high magnetizing inrush current. 4. After charging. This may be checked for operation of each Master Trip Relay for 2 or 3 protective relays.89 0. Max.0 Last Updated : 31-1-2008 . Min. 6. Water Content (ppm).2 18.4 18. After re – charging. The limits as recommended in Table – 1 of IS 1866: 2000 are also given below. Resistivity (90ºC) × 1012 (ohm – cm).

5 1. c) Reconnect the linkage of the individual pole to the operating lever. shall be done in a manner such that the inner diameter of the pipe is not reduced.2 3. erect the base channel along with breaker poles on the supporting structures. Cutting of the pipes. and the support columns if provided. Level the top of the already erected supporting structure(s) and check their verticality. Release the moving contact rod suddenly. Bending of compressed air piping. b) Pull the moving contact rod of each interrupter manually towards ‘OPEN’ position during which operation appreciable force should be encountered.3 3.0 2.3 4. This should be done through cold bending using a bending machine only.4 1. 1.CHAPTER – 6 CIRCUIT BREAKERS 1. Erection of Circuit Breaker Poles: In case of CBs received with poles already fitted on a common base channel.1 4. tested and commissioned as per the instructions given in the Erection. Erect the supporting structure(s) on the foundation and carry out their levelling. wherever required. by opening the cover of the pipe connection and pressing the non – return valve. Installation & Commissioning Manual of the Manufacturer. In case of Vacuum Circuit Breakers. first erect the base channel on the supporting structure(s) and carry out levelling. Erection of Supporting Structures: Assemble the supporting structure(s) if the members are received in loose condition.2 Last Updated : 31-1-2008 . check the vacuum in the individual poles as follows: a) Remove the linkage of the individual pole from the operating lever. It should return automatically to ‘CLOSED’ position with a loud metallic noise.2 1.3 1.1 2. The SF6 gas should be filled in one pole at a time to ensure that gas is filled in all the three poles.6 2. Erect the middle pole first followed by the side poles.0 1. check that there is positive pressure of the SF6 gas in the breaker poles. erect the poles on the base channel. Only a proper pipe – cutting tool shall be used. Preparation & Checking of the Circuit Breakers Poles: Clean the insulators of the breaker poles and check for cracks in the insulators. Thereafter.1 3. In case of CBs with common base channel but in which the poles are received separately. In case of SF6 Circuit Breakers. The procedure / steps generally followed for erection of Circuit Breakers are given below.2 2. The services of the Manufacturer’s Erection & Commissioning Engineer may be utilized wherever required.1 GENERAL INSTRUCTIONS: The circuit breakers are to be erected. if required. centering and grouting.0 4.0 3. shall be done such that there is no flaring of the ends of the pipe.

or as applicable.2 Last Updated : 31-1-2008 . erect it on its foundation and carry out its centering.1 4. erect the control cubicle on the supporting structure / base channel as provided. For Gang Operated Circuit Breaker: Connect the operating shaft / rod between the poles and between the first pole and the mechanism. the operating mechanism is generally received mounted on the assembled structure. Fit the protective covers for operating shaft / rod. Connect the SF6 gas pipeline to one pole & fill SF6 gas in the pole up to about 2 kg / cm2. first erect the operating mechanisms on the supporting structures and carry out levelling. In other cases. Thereafter erect the arc chamber assemblies on the support columns of individual phases.72 Construction Manual for Sub Stations 4. erect the CB poles on the supporting structures. Accessories & Associated Equipment: In case of ground mounted control cubicle. if provided. Gas Filling in SF6 Gas Circuit Breakers: CBs with Common SF6 Gas Pipeline: Fit the SF6 gas density monitor on the support structure / base channel as provided and connect to the SF6 gas pipeline. levelling and grouting. if provided. Erect the operating mechanism / operating drive on the supporting structure of the designated phase. on its foundation & carry out its centering.4 6. In other cases. or on the common base channel.0 6.1 7. Thereafter.7 4. In case of CBs with horizontal arc chambers. Fit the pre – insertion resistors and voltage grading capacitors.1 5.1 7. Check for leakage of SF6 gas in the pole and in the SF6 gas pipeline.5. if any.6 4. Check the verticality of the erected poles of the CBs and correct the same wherever required.2 6.8 5. if provided separately. Place the air compressor.1 6. or on all the three individual phases / poles.5. erect the CB poles on the operating mechanisms.3 7. Attend to the leakages. levelling and grouting. Erection of Operating Mechanism. erect it on its foundation and carry out its centering.1.2 5. IMPORTANT: DO NOT CHANGE OR ADJUST THE LENGTH OF THE OPERATING SHAFT / ROD. as applicable. first erect the support columns on the supporting structures.1. In case of ground mounted operating mechanism. 4.0 7.0 5.4 4. In case of other types of CBs. levelling and grouting.3 4. Fit the terminal connectors on the three poles of the breaker.5. erect the operating mechanism on the supporting structure / base channel as provided. on the arc chambers.3 5.3 In case of CBs in which the poles are to be erected on the operating mechanism. In case of circuit breakers up to 33 kV. or on the common structure.2 4.

Fill SF6 gas in each pole one by one up to about 2 kg / cm2.4 to para 7.Circuit Breakers 73 7. Thereafter.1.8 7.g. Check phase sequence of the A. CBs with SF6 Gas Density Monitors on Individual Poles: Fit the SF6 gas density monitor on each pole alongwith pipeline if provided. Attend to the leakages. supply to the air compressor and check direction of rotation of air compressor motor. one end of the pipeline is connected to the air compressor and the other end is plugged.. couplings.10 7. Fit the pipeline as per drawing.2 8. if any. provided in the density monitor. Check for leakage of SF6 gas in the poles and in the SF6 gas pipeline.3 7. Finally fill SF6 gas in all the three interconnected poles up to prescribed rated / filling pressure. Connect the SF6 gas pipeline to the third pole. 7. Check for leakage of SF6 gas in the second pole. The procedure from para 7. The gas pressure in the first pole will fall.3 Last Updated : 31-1-2008 . if any. joints. Attend to the leakages.2. if any.1.2. are checked during SF6 gas filling. etc.9 7.2.9 ensures that SF6 gas is filled in all the three poles. A small air pressure is injected in the pipeline and then suddenly released by removing the plug so that the pipeline is flushed.1 7. The pipeline is first cleaned by passing a mulmul cloth through it with the help of a wire.11 7.1.1.2. Check for leakage of SF6 gas from all the points (e.C.1.5 8.1. Check for leakage of SF6 gas in the third pole. Attend to the leakages.0 8.2.2 7.) and attend if any leakage is detected.2 7. Connect the SF6 gas pipeline to the second pole. Ensure that the alarm and lockout contacts are in normal condition after SF6 gas filling.7 7. brazing. Check operation of the alarm and lockout contacts provided in the density monitor during SF6 gas filling. Check and top up oil in the air compressor.1.4 7. Circuit Breakers having Pneumatic Operated Mechanism: Fabricate the compressed air pipeline as per pipe layout drawing & clean it.5 7. The filling pressure should correspond to the ambient temperature at the time of filling as per the chart given in the manufacturer’s manual.6 7.1. Fill SF6 gas up to prescribed rated / filling pressure in each pole one by one. Also check that the V – belt is at the correct tension. Fill the SF6 gas in the two poles simultaneously up to the prescribed rated / filling pressure.3 Fill SF6 gas in the pole up to the prescribed rated / filling pressure.1. The filling pressure should correspond to the ambient temperature at the time of filling as per the chart given in the manufacturer’s manual.4 7.1.1 8. The setting and operation of the lockout contacts (closing) and the alarm contact (opening). Ensure that the alarm and lockout contacts are in normal condition after SF6 gas filling. cementing on insulator & metallic joints.1.

“Auto Reclose Blocking” & “Low Air Pressure Lockout”. “Auto Reclose Lock out”.8 9. etc. “Auto Reclose Lock out”. Fill hydraulic oil. Check phase sequence of the A. joints. Check operation of safety valve and verify its setting. of the designated grade as supplied with the Circuit Breaker. Switch off the A.2 9. 8. and “Low Oil Pressure Lockout”.g.8 9.4 9. During the rising pressure. for “Compressor Start”.1 9. During falling pressure. C. Open the drain valve on the air storage tank such that air is released slowly.7 9. Pressurize the compressed air pipeline to the rated pressure. couplings. as per manufacturer’s recommendations. joints. During increasing pressure. as and when required.9 9.4 Pressurize the compressed air pipeline and air storage tank(s) to about 5 kg / cm2 and check for air leakage from all possible points (e. Check for oil leakage from all the points (e. check operation of pressure switches and verify their settings for “Oil Pump Start”. check the operation of pressure switches and verify their operating and differential settings. couplings. brazing. to maintain oil level in the storage tank.5 9. for “Low Air Pressure Lockout”. in the storage tank(s) up to the fill mark. supply to the compressor. check the operation of pressure switches and verify their settings.74 Construction Manual for Sub Stations 8. “Low Air Pressure Alarm” & “Compressor Stop”. check operation of pressure switches and verify their settings for “Low Oil Pressure Lockout”.. Adjust the pressure settings if required. stop the oil pump motor and adjust the setting to the required value and re – verify this setting. stop the air compressor and adjust the setting to the required value and re – verify this setting. “Auto Reclose Blocking”.) and attending to the leakages if detected. Check the auto / manual operation of air compressor.. If the safety valve does not operate even when the prescribed pressure is exceeded. Open bypass valve to reduce the oil pressure. Open bypass valve to reduce the oil pressure to normal.6 9. If the safety valve does not operate even when the prescribed pressure is exceeded. Drain air so as to maintain normal pressure in the storage tank(s). Start the oil pump motor and release air from the venting screw(s) provided. During the falling pressure. supply to the oil pump motor and check its direction of rotation. Check operation of safety valve and verify its setting.10 Last Updated : 31-1-2008 . “Low Air Pressure Alarm”.C. Top up oil. “Low Oil Pressure Alarm” & “Oil Pump Stop”.) and attend to the leakages if detected. Check the auto / manual operation of the oil pump.6 8. “Low Oil Pressure Alarm”. Circuit Breakers having Hydraulic Oil Operated Mechanism: Clean all the prefabricated hydraulic oil pipes by passing a mulmul cloth through them with the help of a wire. Build up pressure in the hydraulic oil pipeline. Start the compressor in the manual mode and build up pressure.7 8.3 9. brazing. Start the oil pump in the manual mode and build up pressure. control blocks. as per manufacturer’s recommendations.g. etc. Fit the prefabricated hydraulic oil pipeline as per drawing.0 9.5 8.

i) Auto Trip / Spring Charged Lamp indication. a) DC positive & DC negative for local operation. 10. Y & B) and control cubicle. Cabling & Wiring: Carry out laying of cables between the following: i) Operating mechanisms of individual phases (R. Dress and fix the cables in cable trays / trenches / supports / brackets. iii) Density Monitor and control cubicle.5 11. g) Trip circuit supervision. e) Remote tripping signal. v) Control cubicle and bay marshalling kiosk.1 11. iv) Control cubicle and Control & Relay Panel. Fix the cables in cable glands and then fix the cable glands on cable gland plates in the respective equipment.3 10.3 11. c) DC positive for remote tripping.0 10. The following typical connections are made at the circuit breaker end. iii) V – belt is properly tensioned.0 11. h) ON / OFF indications (Lamp & Semaphore).0 12. if applicable. iii) Air filter is clean. m) Auxiliary contacts as required for various control circuits.1 Circuit Breakers having Spring Operated Mechanism: ENSURE THAT THE CLOSING SPRING IS FULLY DISCHARGED. Take all the precautions mentioned in the manufacturer’s manual.2 11. Discharge the spring as per directions in the manufacturer’s manual. Carry out slow mechanical operation (closing and tripping) of Circuit Breaker as per procedure prescribed by the manufacturer. l) Contact for annunciation of pole discrepancy trip alarm. Charge the spring electrically and verify the operation of the limit switch. Adjust the setting of the limit switch if required.4 12. If it is not fully discharged.1 Last Updated : 31-1-2008 . j) Air pressure / Oil pressure / Spring charging limit switch contacts for auto reclose blocking. Manually charge the closing spring and check electrical limit switch. f) Protection trip signal. ii) Compressor and control cubicle.2 10. then discharge the spring as per instructions given in the manufacturer’s manual.4 10. PRE – COMMISSIONING CHECKS: Check the following in the Air Compressor: i) Oil level is upto the mark. mechanical latches and stopper(s) as provided.Circuit Breakers 75 10. k) Contacts of pressure switches for annunciations of low SF6 gas / air / oil pressure alarms & lockout conditions and for loss of N2 pressure. b) DC positive for remote closing. d) Remote closing signal. Connect the cables as per schematic diagram of the circuit breaker. ii) Oil colour is not black.

The oil level should be between the maximum & minimum level marks. Check alarm annunciations in the C&R Panel for low SF6 gas / hydraulic oil / air pressure alarm. Check the oil level in the oil storage tank(s) of all the three poles of CBs with hydraulic oil operated mechanism. remote and protection.76 Construction Manual for Sub Stations 12. as applicable.13 12. Check and adjust the resistance in the closing / tripping coil circuits. Check resistance of closing and tripping circuits. as applicable. Check operation of dash pot / damper. as applicable. Check the pressure of SF6 gas / hydraulic oil / air in the circuit breaker.9 12. Check earthing of the poles. Check functioning of space heater and internal illumination circuits. Check the contact wear indication mark or the specified gap as given in the instruction manual in case of Vacuum Circuit Breakers with the circuit breaker in the closed position.10 12.11 12.1 Last Updated : 31-1-2008 . It should damp the speed of the Circuit Breaker at the end of both closing and tripping operations. Lubricate all the moving parts and the pins in the operating mechanism. PRE – COMMISSIONING TESTS: Measure insulation resistance with 5 kV megger of all the three phases between lower terminal to earth and between upper and lower terminals with the breaker in the open position. Check clamping of the pipe line for SF6 gas / hydraulic oil / air. Check the Trip Circuit Supervision circuits in both CB open and closed conditions by removing the wires of the tripping circuit.17 12. as applicable. Confirm that the correct pole of the Circuit Breaker has operated. Check closing and opening operation of circuit breaker from local. in the C&R Panel for CB OPEN. if required.5 Check SF6 gas / hydraulic oil / air leakages.20 13. AUTO TRIP and SPRING CHARGED conditions. if provided. CLOSED. The breaker should close and then trip and should not close again. base channel.18 12. 12. Check functioning of operation counter. and its alarm annunciation in the C&R Panel.8 12. if provided. as applicable. and attend if required. Check closing of Circuit Breaker through auto – reclose scheme. Check operation of anti – pumping / hunting relay by giving continuous closing and tripping signals simultaneously.7 12.4 12.16 12. top up with oil. as applicable.2 12. Check settings of air / oil pressure switches.0 13. control cubicle. Check operation of pole discrepancy relay. operating mechanism.14 12. SF6 gas / hydraulic oil / air pressure lockout and loss of N2. Check lamp and semaphore indications.19 12.15 12.12 12. compressor and structure(s).3 12. otherwise.6 12.

Last Updated : 31-1-2008 . Since the above facility is not available. (a) (b) 33 kV CB 11 kV CB 70 kV 28 kV 13. if provided. apply the voltage as given below across the upper & lower terminals of the VCB for 60 seconds.3 13.4 The vacuum interrupters should withstand the applied voltage.2 Measure Closing (C). Test the operation of the CB with the emergency tripping arrangement. Opening (O) and Close – Open (CO) operation timings of the breaker with CB Timer or CB Analyser. Manufacturers of Vacuum Circuit Breakers recommend the following method for testing the vacuum in the interrupters with the circuit breaker in ‘OPEN’ condition: Using high voltage testing equipment.Circuit Breakers 77 13. check the vacuum as given at para 3.3 above.

78 Construction Manual for Sub Stations Last Updated : 31-1-2008 .

15 1. moving contacts are fitted on the polycone insulators / insulator stacks. for erection of the Isolator and operating mechanism(s).4 1. 1. there will be six polycone insulators / insulator stacks whereas for double break Isolators.12 1.5 1.10 1. base frames of individual phases on the structure(s).6 1. Fit the fixed contacts of earth blades in case of Isolator with Earth Switch. Carry out levelling and centering of the base frames. 6 nos.0 2. 1.CHAPTER – 7 ISOLATORS 1. if required.1 2. Fit the main operating down pipe to operating mechanism for the Isolator. fixed contacts and 3 nos.13 1. Fix the link pipes on the rotating parts of the base frames of the individual phases.9 1. Clean and assemble the polycone insulator / insulator stack.8 1. as applicable.1 ERECTION OF ISOLATORS: Level the already erected structure(s) and carry out minor fabrication works. Fix the arcing horns (make before & open after the main contacts) or corona rings.16 2. Check the operation and final adjustment / alignment of all the three phases of main Isolator for smooth. as applicable. synchronized and complete operation as one unit. Adjust the mechanical end stoppers on the base channel for both the closed and open positions. In case of double break Isolator. Fit the operating mechanism box for the Isolator.14 1. Carry out adjustment / alignment of individual phases for smooth opening and closing and proper making of contacts. wherever provided. Fit the terminal connectors on the Isolator. including fixing of hardware for interlocking with earth switch wherever provided. Fit the male and female contact arms on the polycone insulators / insulator stacks in case of single break Isolator. For single break isolators. ERECTION OF EARTH SWITCHES: Fix the earth blade mounting arrangements on the base frames of all the three phases. the quantity will be nine. Erect the 3 nos.2 1. Fit the moving contact (earth blade) of the earth switches and counterweights.11 Fit the inter – phase connecting pipes between the rotating parts of the base frames of the individual phases.0 1.3 1.7 1. Erect the above assemblies on the rotating parts of the base frames.2 Last Updated : 31-1-2008 .

OPERATING MECHANISM: Carry out the adjustment and setting of auxiliary switches.10 3.0 4. a) DC positive & DC negative for local operation.2 4. Carry out the adjustment of mechanical end stoppers for the OPEN position of earth switch. Cabling & Wiring: Carry out laying of cables between the following: i) Operating mechanisms of individual phases (R. Y & B) in case of individual phase operating mechanism.3 3. and that main Isolator does not operate if the earth switch is closed.4 4. The following typical connections.0 3. i) Auxiliary contacts as required for various control circuits. Fit the inter – phase connecting pipes between the earth switches of the individual phases.6 2.4 2.1 3.3 Carry out the operation and adjustment / alignment of earth switch of each phase for smooth opening and closing and proper making of contacts. Carry out the adjustment of mechanical end stoppers for both the CLOSED and OPEN positions. Fit the main operating down pipe to operating mechanism for the earth switch. 2. Carry out the adjustment and setting of mechanical interlock between main Isolator and earth switch to ensure that earth switch does not operate if the main Isolator is closed.3 4. Dress and fix the cables in cable trays / trenches / supports / brackets. ii) Operating mechanism and Control & Relay Panel. d) DC positive for remote opening. g) OPEN / CLOSE indications (Lamp / Semaphore). Carry out the adjustment of interlocking coil and plunger in CLOSED and OPEN positions. are made at the isolator and earth switch end.9 2. as applicable. Connect the cables as per schematic diagram of the isolator and earth switch. Fix the cables in cable glands and then fix the cable glands on cable gland plates in the respective equipment.8 2.1 4.5 2.80 Construction Manual for Sub Stations 2. f) Remote opening signal.4 Last Updated : 31-1-2008 .7 2. Fit the operating mechanism box for the earth switches. synchronized and complete operation as one unit. h) Contact for annunciation of pole discrepancy trip alarm. Carry out the adjustment of limit switches in CLOSED and OPEN positions of Isolator in case of motor operated mechanism. c) DC positive for remote closing. Fit the earth bonds and other accessories as provided. iii) Operating mechanism and bay marshalling kiosk.2 3. Check the operation and final adjustment / alignment of all the three phases of the earth switch for smooth. including fixing of hardware for interlocking with main Isolator. e) Remote closing signal. b) Interlocking supply.

2 Last Updated : 31-1-2008 . supply to the motor and check direction of rotation of isolator. Check earthing of moving parts such as operating handles of isolators.2 6.Isolators 81 5. Check earthing of the operating mechanism. as provided. as applicable.10 5. if applicable. which should be earthed through flexible earthing connectors.0 6. in the C&R Panel for Isolator and earth switch OPEN and CLOSED conditions. if applicable.3 6. including interlocking between main isolator and earth switches. Check operation & verify setting of overload relay / MCBs for motor.0 5. Check operation of the electrical emergency opening arrangement.7 5. Check operation of electrical limit switches in motor operated mechanism.1 PRE – COMMISSIONING CHECKS: Lubricate all the moving parts and the pins of the Isolator & earth switch and in the operating mechanism.1 7. 5. ii) Complete insertion and making of contacts in close position.9 5.3 5.5 5. Check lamp / semaphore indications. v) Setting of end stoppers in close and open conditions.2 5.C.1 6. Check earthing of the main Isolator and earth switch. Check functioning of space heater and internal illumination circuits in the motor operated mechanism. vi) Operation of auxiliary switches. if provided. Check phase sequence of the A. Keep the isolator in half closed position before checking the phase sequence. if provided.11 6. Check operation of Isolator and earth switch for following: i) Smooth operation.8 5.6 5.4 7. Measure the Contact Resistance of 400 kV Isolators in the CLOSED position.0 7. Check operation of interlocking coil in the Isolator and earth switches. if provided. GENERAL CHECKS: Re – check the adjustment / alignment of the Isolator main contacts for smooth opening and closing and proper making of contacts after jumpering on both sides. for Bus Isolators. Check local and remote electrical operation of the isolator. iv) Functioning of mechanical interlock between main Isolator and earth switch. Check operation & verify setting of timer for Isolator operation and pole discrepancy. Also check operation of voltage selection relay. PRE – COMMISSIONING TESTS: Measure the insulation resistance with 5 kV megger of each phase to earth in the Isolator CLOSED position.4 5. iii) Complete opening of contacts in open position.

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it must be ensured that the P1 terminal is towards the Main Bus side. 1. The secondary windings are rated for 1 Amp or 5 Amp. 125 – 250 – 500. 1.5 / 1. Core 1 PS Differential Protection 2. Core 2 0. Core 3 0. 1. Core 5 0.5 Metering 33 kV Feeders CT Ratios: 60 – 120 – 240. Core 2 5P20 Over current & Earth fault Protection 3. Core 1 PS Differential Protection 2. 1. Core 4 PS / 5P20 Bus Bar Protection 132 kV side of 132 kV class Transformers CT Ratios: 60 – 120 – 240. 250 – 500.5 Metering: Indication & Energy Meter 1. Core 2 5P20 Over current & Earth fault Protection 3. 1200. 250 – 500. Core 3 0.CHAPTER – 8 CURRENT TRANSFORMERS 1. Core 3 0.5 Metering: Indication & Energy Meter 33 kV side of 132 kV Class Transformers CT Ratios: 150 – 300 – 600. Core 1 5P20 Over current & Earth fault Protection 2.1 GENERAL INSTRUCTIONS: While erecting the Current Transformers. Core 2 0.5 Metering: Indication & Energy Meter 4. Core 2 PS / 5P20 Over current & Earth fault Protection 3. 1.0 Metering: Indication 4. Core Number Accuracy Class Purpose 11 kV Feeders CT Ratio: 100 – 200 – 400.0 1.2 Metering: Check Energy Meter 132 kV Feeders at 132 kV GSS CT Ratios: 100 – 200 – 400. 125 – 250 – 500. Core 1 5P20 Over current & Earth fault Protection 2. Core 2 PS / 5P20 Over current & Earth fault Protection 3. 250 – 500. Core 3 0. 1. No. Core 1 PS Distance Protection 2. Core 4 0. Core 1 PS Distance Protection 2. 1. Core 1 PS Differential Protection 2. Core 2 PS / 5P20 Over current & Earth fault Protection 3. The different cores of the secondary winding of the Current Transformers are used for the following purposes.2 Last Updated : 31-1-2008 .5 Metering: Indication & Energy Meter 132 kV Feeders at 220 kV GSS CT Ratios: 100 – 200 – 400. Core 3 0.2 Metering: Main Energy Meter 5.5 Metering 11 kV side of 132 kV Class Transformers CT Ratios: 200 – 400 – 800.

Core 1 PS Differential Protection Main – 1 / Distance Protection Main . Core 3 0. Earth fault and LBB Protections 3. Core 2 PS Differential Protection Main – 2 / Distance Protection Main – 2. 400 – 800. Core 4 PS Bus Bar Protection (Main Zone) 5. Core 2 PS Differential Protection Main – 2 / Distance Protection Main – 2.5 Metering 4. 250 – 500. Core 3 0. Core 5 PS Bus Bar Protection (Check Zone) 220 kV side of 220 kV class Transformers CT Ratio: 150 – 300 – 600. Core 5 PS Bus Bar Protection (Check Zone) 400 kV Bays CT Ratio: 500 – 1000 – 2000. 1.5 Metering: Indication & Energy Meter 4.5 Metering 4. Core 4 PS Bus Bar Protection (Main Zone) except for CTs in Tie CB Bay 5. 3. Core 1 PS Differential Protection Main – 1 / Distance Protection Main – 1 2. Over current. 1. Earth fault and LBB Protections 3.1 2.3 Ferrule markings as mentioned below are generally used as prefix for indicating the wires of different cores of the Current Transformers: S. Core 5 PS Bus Bar Protection (Check Zone) 220 kV side of 400 kV class Transformers CT Ratio: 500 – 1000 – 2000. 1. 4. 400 – 800. Core Number Accuracy Class Purpose 132 kV side of 220 kV class Transformers CT Ratios: 150 – 300 – 600. Core 1 PS Distance Protection Main . Core 5 PS Bus Bar Protection (Check Zone) except for CTs in Tie CB Bay 1. Core 2 PS / 5P20 Over current & Earth fault Protection 3. Core 3 0. 1. Earth fault and LBB Protections 3.84 Construction Manual for Sub Stations No. Earth fault and LBB Protections 3.5 Metering 4. CT CORE USED FOR Differential / Distance Protection Bus Bar Protection Over current & Earth fault (Back up Protection) Metering PREFIX FERRULE A B C D Last Updated : 31-1-2008 . 2. Over current. Core 4 PS Bus Bar Protection (Main Zone) 5. 1. Over current. Core 2 PS Over current. Core 4 PS / 5P20 Bus Bar Protection 220 kV Feeders CT Ratios: 200 – 400 – 800. Core 3 0. 1. Core 3 0. Core 4 PS Bus Bar Protection (Main Zone) 5. Core 1 PS Differential Protection 2.1 2. Core 2 PS Distance Protection Main – 2. No. Core 1 PS Differential Protection 2.5 Metering 4.

Y & B phases) to the Marshalling Kiosk / Junction Box. A typical wiring connection for Core – 1 of Current Transformers in the Bay Marshalling Kiosk / Junction Box is shown below: 2.4 2. Clean the insulator of the Current Transformer. Dress and fix the cables in cable trays / trenches / supports / brackets.Current Transformers 85 2.4 3. if required. Cabling & Wiring: Carry out laying of cables from secondary terminal box of the Current Transformer to the bay Marshalling Kiosk (MK) / Junction Box.5 3. Measure the IR values of primary terminals to earth with 5 kV Megger.3 2. The secondary windings of different phases of Current Transformers are generally star connected.2 3. for erection of the Current Transformer.3 3. Fit the terminal connectors on the Current Transformer. Fix the cables in cable glands and then fix the cable glands on cable gland plates in the respective equipment.2 2.0 2.6 Last Updated : 31-1-2008 .0 3.1 ERECTION: Carry out levelling of already erected structure(s) and minor fabrication work. All the cores of Current Transformer which are not used must be shorted and earthed in the Marshalling Kiosk / Junction Box.1 3. Erect the Current Transformer on the structure.5 3. Connect all the cores of the secondary winding from the secondary terminal box of Current Transformers (R.

0 4.6 6.1 5.86 Construction Manual for Sub Stations 4. Checking of use of the secondary windings as per their accuracy class / knee point voltage / burden for protection / metering. Check that all the spare cores of the secondary winding of the Current Transformer have been shorted and earthed. Verification of all the current ratios between the primary winding and all the secondary windings. Check the oil level in the Current Transformer.1 PRE – COMMISSIONING CHECKS: Check tightening of connections of wiring of the secondary windings in the secondary terminal box of Current Transformer and also in the Marshalling Kiosk / Junction Box. 33 KV AND 11 KV INSTRUMENT TRANSFORMERS (CT’s. Checking of continuity of the current circuit of the secondary windings and the verification of phases (R.0 5.3 4.0 Last Updated : 31-1-2008 . etc.3 5. ELECTROMAGNETIC PT’s AND CVT’s)” of RVPN (erstwhile RSEB) should be followed. For operation and maintenance of Current Transformers. Check the earthing of the Current Transformers and Marshalling Kiosk / Junction Box.2 5. Verification of polarity between the primary winding and all the secondary windings.2 4. the “MAINTENANCE MANUAL FOR 132 KV. Check that the star / neutral formation of the secondary windings of the three phases of the Current Transformers has been made correctly.5 4. 4. B) by applying current through primary injection in each Current Transformer and measuring the current in the respective equipment in the control room. Y.. PRE – COMMISSIONING TESTS (By Protection Wing): Measurement of insulation resistance between primary winding to earth. primary winding to all the secondary windings with 5 kV Megger and all secondary windings to earth with 500 V Megger. Check that the neutral point of the secondary windings has been earthed in the Marshalling Kiosk / Junction Box. Testing of knee point voltage of all the protection cores. for each core at a time while shorting all the other cores in the Current Transformer.4 4.6 5.4 5. such as meters and relays.5 5.

2 0. if applicable. Erect the Capacitor Voltage Transformer / Potential Transformer on the structure. Core 2 3.5 Last Updated : 31-1-2008 . Measure the IR values of primary terminal to earth with 5 kV Megger.2 2. Core 2 220 kV 1.2 A ferrule ‘E’ is generally used as prefix of the ferrule markings for indicating the wires of different cores of the VTs. Core Number 11 kV 1. Core 1 2. Core 1 2. The term Voltage Transformer (VT) is used to cover both PT and CVT.0 2. and Capacitor Voltage Transformers (CVT) are used for protection and metering.1 2. generally referred to as Potential Transformers (PT). Clean the insulators of the VTs.0 1. ERECTION: Carry out levelling of already erected structure(s) and minor fabrication work.5 0.5 3P 0. Core 2 3.5 0. The secondary windings are rated for 110 / √3 Volts. Core 1 2.No. Core 1 2.4 2. Core 3 132 kV 1.5 3P 3P 0. This shorting may be temporarily removed for testing. Core 2 33 kV 1.5 Metering Metering Metering Metering Metering Protection & Metering (connected in star) Directional Earth Fault Protection (connected in open delta) Protection & Metering (connected in star) Directional Earth Fault Protection (connected in open delta) Protection (connected in star) Directional Earth Fault Protection (connected in open delta) Protection & Metering (connected in star) Purpose 1. Sl.4 Accuracy Class 3P / 0. Core 2 400 kV 1. Core 1 2. The CVT or its individual units should be kept shorted and earthed to prevent shock from accumulated charge.1 GENERAL INSTRUCTIONS: Electromagnetic Voltage Transformers.5 0. Assemble the different units of the same serial number of the CVT.CHAPTER – 9 CAPACITOR VOLTAGE TRANSFORMERS (CVT) / POTENTIAL TRANSFORMERS (PT) 1. The different cores of the secondary winding of the VT are used for the following purposes. for erection of the Capacitor Voltage Transformers / Potential Transformers.3 1.3 2. Core 3 1. 2.2 3P 0. The shorting should be finally removed before energizing the CVT. if required.

Y & B phases) to the Marshalling Kiosk / Junction Box. One end of these windings must be earthed in the Marshalling Kiosk / Junction Box.1 3.2 3.6 2. Connect all the cores of the secondary winding from the secondary terminal box of VTs (R.6 Fit the covers on the joints between different units of the CVT. if applicable. Typical wiring connections of 2 core CVTs and PTs in the Bay Marshalling Kiosk / Junction Box are shown below: Last Updated : 31-1-2008 . Cabling & Wiring: Carry out laying of cables from secondary terminal box of the VTs to the bay Marshalling Kiosk / Junction Box. The cores of VTs which are not used should be left open. Fit the terminal connectors on the VT’s. Dress and fix the cables in cable trays / trenches / supports / brackets.0 3.3 3.88 Construction Manual for Sub Stations 2.4 3. Fix the cables in cable glands and then fix the cable glands on cable gland plates in the respective equipment.5 3. The secondary windings of different phases of VTs are connected either in star or open delta.7 3.

4 Last Updated : 31-1-2008 . Check that there is no shorting in the wiring of the secondary circuit of the VTs. Verification of polarity between the primary winding and all the secondary windings.2 5. and all secondary windings to earth.6 4. Check the earthing of the VTs. Check that the temporary shorting and earthing of the CVT or its units has been removed. Verification of all the voltage ratios between the primary winding and all the secondary windings. Verification of use of the secondary windings as per their accuracy class / burden for protection / metering.3 4. Check that the formation of the star / neutral point or open delta connections of the secondary windings of the three phases of the VTs has been made correctly and that the neutral end of the star connected winding and one end of the open delta connected winding have been earthed in the Marshalling Kiosk / Junction Box.7 5. 4.1 4.Capacitor Voltage Transformers (CVT) / Potential Transformers (PT) 89 4. Check that the fuses provided in the VT secondary circuits are of correct rating and that there is proper grading of the fuses. Check the tightness of the connections of the wiring of the secondary windings in the secondary terminal box and in the Marshalling Kiosk / Junction Box.3 5. PRE – COMMISSIONING TESTS (By Protection Wing): Measurement of insulation resistance between primary winding to earth.0 4.2 PRE – COMMISSIONING CHECKS: Earth the HF Terminal of CVT.1 5.0 5.5 4.4 4. if it is not used for PLCC system. primary winding to all the secondary windings.

0 Last Updated : 31-1-2008 .5 Verification of the connections of the voltage circuit of the VT secondary windings and verification of the phases (R. 6. 33 KV AND 11 KV INSTRUMENT TRANSFORMERS (CT’s. the “MAINTENANCE MANUAL FOR 132 KV. ELECTROMAGNETIC PT’s AND CVT’s)” of RVPN (erstwhile RSEB) should be followed. Y. etc. For operation and maintenance of Capacitor Voltage Transformers / Potential Transformers (CVT’s / PT’s). for each core at a time while keeping all the other cores in the VT disconnected. B) by applying voltage through variac in each wire of the control cable from the VT to the control room.. such as meters and relays.90 Construction Manual for Sub Stations 5. and measuring the voltage at all points in the respective equipment in the control room.

0 3. Fit the terminal connectors on the Lightning Arresters.4 2.1 GENERAL INSTRUCTIONS: The serial number of all the units of a multi – unit Lightning Arrester (LA) should be the same.2 1. 25 mm) between the structure and the connection from the bottom most unit of the Lightning Arrester to the Surge Monitor as shown in the drawing below: 1.7 2. Erect the Lightning Arresters on the already erected and levelled supporting structure(s). Fit the terminal connectors on the Lightning Arresters.6 2.3 2. The units of a multi – unit Lightning Arrester should be assembled in the sequence shown on the rating plate of the LA or in the catalogue of the manufacturer.1 3. The installation of the Lightning Arresters should be such that the direction of the open end of the explosion release vent (at top & bottom) is away from adjacent expensive equipment such as transformers.5 2.1 Last Updated : 31-1-2008 .0 4. if provided.1 2.8 3. Erection of LAs of 132 kV Class & Above: Level the already erected supporting structure(s) and carry out minor fabrication work thereon for erection of the Lightning Arresters and surge monitors.4 4. PRE – COMMISSIONING CHECKS: Ensure that there is appropriate clearance (Min.CHAPTER . as required. Also. carry out fitting of the corona rings between different units. Erect the Lightning Arresters on the already prepared arrangement on the beam of the substation structures. Clean the insulators of the Lightning Arresters.3 1.0 1.3 3.2 3. Fit the Surge Monitor on the structure and connect it to the lowest unit of the Lightning Arrester above the base insulator. Assemble the different units of the same serial number of the Lightning Arresters. Fit the corona / grading ring on the top of the Lightning Arrester.10 LIGHTNING ARRESTERS 1.0 2. The insulated base unit should be erected in case of Lightning Arresters provided with surge monitors. if provided. Erection of 33 kV & 11 kV LAs: Make mounting arrangements on the beam of the already erected sub – station structures.4 2. if applicable. Clean the insulators of the Lightning Arresters.

92 Construction Manual for Sub Stations 4. Note down the initial readings of the surge counters in the Surge Monitors. check the tightness of the connection between the Lightning Arrester and the Surge Monitor.0 Last Updated : 31-1-2008 . if applicable. PRE – COMMISSIONING TESTS: Measure the insulation resistance of individual units of the Lightning Arrester.2 For LAs of 132 kV class & above. Measure the insulation resistance between line end of LA to earth with 5kV Megger. Check the leakage current meters in the Surge Monitor after the Lightning Arresters are energized. and between the Surge Monitor and earth. The reading should be well within the “green zone” marked on the scale of the leakage current meters.0 5. with 5 kV Megger.1 5. 4.4 5. Check the tightness of the earthing connection of the Lightning Arrester for 33 kV & 11 kV LAs.2 6.3 4.

3 1. Fit the corona ring on the Post / Polycone Insulators.0 1. Fit the clamps on the Post / Polycone Insulators.4 1.1 PRE-COMMISSIONING TESTS: Measure the insulation resistance between top and bottom part of the Post / Polycone Insulators with 5 kV Megger.0 3.CHAPTER . Clean the Post / Polycone Insulators. 3. if provided. Assemble the parts of Post / Polycone Insulators. if required. Last Updated : 31-1-2008 .0 2. 2.6 ERECTION: Level the top plate of the already erected structure for Post / Polycone Insulators.5 1.1 PRE-COMMISSIONING CHECKS: Check the tightness of the earthing connection of the base of the Post / Polycone Insulators.1 1.2 1.11 POST / POLYCONE INSULATORS 1. Erect the Post / Polycone Insulators on the already erected supporting structure.

94 Construction Manual for Sub Stations Last Updated : 31-1-2008 .

Fit the Wave Trap on the already erected suspension string assemblies through suitable attachment. ERECTION OF SUSPENSION TYPE WAVE TRAPS: Fit the hardware for fixing the Wave Trap to the suspension string assemblies of the designated phases.0 4.3 2.0 2. ERECTION OF PEDESTAL TYPE WAVE TRAPS: Level the top plate of the already erected structure for wave trap.2 3.2 2.12 WAVE TRAPS 1. Hoist the Wave Trap through lifting arrangement on the beam of the sub-station structure. Erect the polycone insulator(s) on the supporting structure. Single Circuit 2. Line Type Type of Coupling Phase to Phase Inter – circuit Phases on which Wave Traps are to be erected Two phases of the line Same phase of both the circuits 1.4 3.3 For single circuit lines.3 4. the Wave Traps are generally erected on the Y phase of both the circuits. the Wave Traps are generally erected on R & B phases. Fit the end covers on the wave traps. if applicable. Erect the Wave Trap on the polycone insulators. then the connecting plate between the joints of the parts of the Polycone Insulators is also fitted.2 1.4 4. Fit the tuning pot and associated equipment in the Wave Trap. Double Circuit 1. 1.2 and para 1.1 2.CHAPTER . For double circuit lines.1 GENERAL INSTRUCTIONS: The Wave Traps are erected as below.3 above in case the end to end return loss is not found satisfactory during testing of the PLCC Carrier Sets.2 4.1 3.4 2.0 3. Assemble the parts of the Polycone Insulators. and position them correctly.1 4.5 Last Updated : 31-1-2008 . Fit the terminal connectors on the Wave Traps.No. S. The Wave Traps may be required to be erected on phases different from those mentioned at para 1.0 1. ASSEMBLY: Clean the Wave Trap and its associated equipment. In case three Polycone Insulators are provided for each Wave Trap and these are in parts.3 4.

96 Construction Manual for Sub Stations Last Updated : 31-1-2008 .

Visual check for any dry solder in the circuits of the LMU / LMDU.1 3.6 2. Fit the co – axial cable on the LMU and LMDU. Check that the strappings inside the LMU / LMDU are connected in the required manner so as to match with the impedance of the co – axial cable (75 ohms / 125 ohms as the case may be).3 3. These CVTs shall be of the same phase on which the wave traps have been / are to be erected. Lay the co – axial cable between LMU and LMDU.4 2.2 3.0 3.4 3.CHAPTER . Fit the LMU / LMDU on the already erected structure.3 2. 2.0 1. Check the tightness of connections in the LMU / LMDU. Check earthing of the LMU / LMDU.1 2. Connect the HF terminal of the Capacitor Voltage Transformer to the HF terminal of the LMU / LMDU. PRE – COMMISSIONING CHECKS: Check the tightness of the connection of HF terminal of the CVT and the connections in the LMU / LMDU. Earth the LMU / LMDU by connecting the earthing terminal to the earth mat. Prepare the ends of the co – axial cable and fix the connectors at the ends.13 LINE MATCHING UNIT (LMU) / LINE MATCHING DISTRIBUTION UNIT (LMDU) 1.5 2.7 3.0 2. designated Capacitor Voltage Transformers (as per coupling requirement) for fixing of Line Matching Unit (LMU) / Line Matching Distribution Unit (LMDU).5 Last Updated : 31-1-2008 .2 2.1 GENERAL INSTRUCTIONS: Open the earthing of the HF terminal of the CVTs and the LMU / LMDU before testing the system. ERECTION: Make arrangements / carry out minor fabrication work (if required) on the supporting structure of the 2 nos.

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Erect the frame of the second phase after erecting post insulators on the frame of the first phase. centering and grouting. including fitting of external fuses if provided. ERECTION OF STRUCTURES: Assemble the structures for the Capacitor Banks.1 GENERAL INSTRUCTIONS: DURING ERECTION WORK ON CAPACTIOR BANKS. Interconnect the capacitor units and phases as per manufacturer’s general arrangement drawing.6 4.3 3. Level the top of the already erected supporting structures and check their verticality. In case only one structure is provided for all the three phases.0 3. CAUTION: CAPACITOR BANKS SHOULD NOT BE SWITCHED ‘ON’ WITHIN 5 MINUTES OF SWITCHING OFF TO ALLOW THE CAPACITOR UNITS TO GET DISCHARGED. Measure the IR values to earth of Series Reactors with 5 kV Megger.0 4. erect the frame of the first phase on the post insulators. ERECTION OF CAPACITOR BANKS: Erect the post insulators on the already erected structure(s).4 3. if the members are received in loose condition.5 3. THE CAPACITOR SHOULD BE KEPT SHORTED AND EARTHED TO PREVENT ELECTRIC SHOCK DUE TO ACCUMULATED CHARGE. In case individual structures are provided for each phase.2 3. Erect the supporting structures on the foundation carry out their levelling. 1. Erect the capacitor units on the already erected frames as per the erection plan of the manufacturer so that the capacitances of all the phases are balanced. In case no erection plan is provided. Series Reactors and Residual Voltage Transformers / Neutral Current Transformers.1 2. measure the capacitance of all the units and make phase wise combinations so that the capacitances of all the phases are balanced.3 3. Refer to instructions in Chapter–11 for erection of post / polycone insulators.2 2. erect the frame of each phase of the Capacitor Bank on the post insulators.2 2.0 2.0 1.14 CAPACITOR BANKS 1. Similarly.2 Last Updated : 31-1-2008 . ERECTION OF ASSOCIATED EQUIPMENT: Clean the insulators of the Series Reactors and Residual Voltage Transformers / Neutral Current Transformers.1 4. erect the frame of the third phase after erecting post insulators on the frame of the second phase.CHAPTER . Fit the post insulators and connecting strips for jumpering as per manufacturer’s general arrangement drawing.1 3.

5 5.0 7.1 5..5 6. Measurement of IR values to earth of Capacitor Banks & Series Reactors with 5 kV Megger.1 7. current transformers and isolators as per instructions in Chapter – 6 for erection of CB. Erect the circuit breaker with supporting structure. Check that there is no shorting and earthing of the Capacitor Units / Banks. Erect the associated equipments.3 Measure the IR values between primary terminal to earth and primary terminal to secondary terminals of Residual Voltage Transformers / Neutral Current Transformers with 5 kV Megger.4 6.2 Fix the cables in cable glands and then fix the cable glands on cable gland plates in the respective equipment.2 6. Series Reactors and Residual Voltage Transformers / Neutral Current Transformers.0 6. 4. Check healthiness and rating of fuses of units of the Capacitor bank. viz. Cabling & Wiring: Carry out laying of cables between the following: i) ii) Residual Voltage Transformers / Neutral Current Transformers and the Marshalling Kiosk / Junction Box. Marshalling Kiosk / Junction Box and Control & Relay Panel. Check setting of timer (5 minutes) for closing interlock for Circuit Breaker (Timer should permit closing of CB only after passage of 5 minutes after tripping of CB).3 Last Updated : 31-1-2008 . Check oil level in the Residual Voltage Transformers / Neutral Current Transformers and Series Reactors (if oil filled).1 6. Connect the cables as per schematic diagram of the Control & Relay Panel. Dress and fix the cables in cable trays / trenches / supports / brackets. Check the earthing of the structures and the equipment.4 6.2 7.6 6.4 4.100 Construction Manual for Sub Stations 4. current transformers and isolators as per instructions in Chapter – 6 for erection of CB.0 5.8 7.3 5. Measurement of IR values between primary terminal to earth and primary terminal to secondary terminals of Residual Voltage Transformers / Neutral Current Transformers with 5 kV Megger. Chapter – 7 for erection of isolators and Chapter – 8 for erection of CTs. PRE – COMMISSIONING CHECKS: Check for proper connections of Capacitor Bank units as per manufacturer’s drawings. 5. PRE – COMMISSIONING TESTS: (By Protection Wing / Capacitor Division) Measurement of capacitance of the three phases of the Capacitor Banks for verifying balancing. Carry out pre – commissioning checks on circuit breaker.7 6. Chapter – 7 for erection of isolators and Chapter – 8 for erection of CTs.

Capacitor Banks 101 7.6 Last Updated : 31-1-2008 . Chapter – 7 for erection of isolators and Chapter – 8 for erection of CTs. Verification of ratio between primary & secondary windings of the Residual Voltage Transformers / Neutral Current Transformers. current transformers and isolators as per instructions in Chapter – 6 for erection of CB. 7. Carry out pre – commissioning tests on circuit breaker.4 Checking of polarity between primary & secondary windings of the Residual Voltage Transformers / Neutral Current Transformers.5 7.

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CHAPTER - 15

EARTHING
1.0 1.1 GENERAL INSTRUCTIONS: Earthing of the Sub Station shall be done as per the earth mat design provided by the Design Wing and in accordance with the latest editions of Indian Electricity Rules, relevant Indian Standards & Codes of Practice and Regulations except where specifically increased / enhanced in the design. a) b) c) 1.2 1.3 IS – 3043: Indian Standard Code of Practice for Earthing. Indian Electricity Rules, 1956 with latest amendments. National Electricity Safety Code, IEEE – 80.

A typical earth mat design of a Sub Station is enclosed as Annexure – A. The details of the earthing material generally used in a sub station are given below: S. No. Description & Size of Material 132 kV Sub 220 kV Sub 400 kV Sub Stations Stations Stations 25 mm dia. 28 mm dia. 40 mm dia. M.S. Rod M.S. Rod M.S. Rod 50 × 10 mm 50 × 12 mm 100 × 12 mm M.S. Flat M.S. Flat M.S. Flat / 75 × 12 mm G.I. Flat 50 × 6 mm 50 × 6 mm 50 × 6 mm M.S Flat M.S Flat M.S Flat

Purpose

1. Main Earthing Conductor for Earth Mat. 2. Earthing Conductor for Risers (for equipments & structures).

3.

Earthing of LT panels, DC panel, C & R Panels, marshalling boxes, Compressors, MOM boxes, junction boxes, lighting panels, etc. 4. Earth Electrodes

5. Earthing conductor along racks of cable trenches 1.4

25 mm dia. M.S. Rod, 3250 mm long N. A.

28 mm dia. M.S. Rod, 3250 mm long N. A.

40 mm dia. M.S. Rod, 3250 mm long 50 × 12 mm M.S. Flat

All equipments and structures are required to be earthed by two separate and distinct connections with earth as per Rule 61 of the Indian Electricity Rules, 1956. The neutrals of all voltage levels of transformers / reactors shall be earthed through independent earthing. All these earthing points should be interconnected with the sub station earth mat. Each earthing lead from the neutral of the power transformer / reactor shall be directly connected to two earth electrodes separately which, in turn, shall be connected to the earth mesh. The transformer / reactor tanks as well as associated accessories like separate cooler banks shall also be connected to the earth mat at two points. Capacitor Voltage Transformers & Lightning Arresters shall be earthed through two independent risers directly connected to earth electrodes which should in turn be connected to the sub station earth mat. The distance between the electrodes should not be less than 4.0 metres.

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All other equipments such as Circuit Breakers, CTs, Isolators, Post Insulators, etc. shall also be earthed at two points. Bus Bar structures and equipment structures shall be earthed at two points. Marshalling boxes, cubicles, C & R Panels and all other metallic enclosures, which are normally not carrying any current, shall also be earthed. All the earthing connections to the earth mat shall be by 2 nos. direct earthing risers free from kinks and of the shortest length. The two earthing connections / risers should be connected to the different sides of the earth mat enclosing the structure / equipment to be earthed. For equipment earthing (including isolators), the earthing risers should be connected to the earthing terminal / pad of equipment and brought down along the leg / main member of structure and connected to the earth mat. The structure shall not be used as a part of the earthing. Burial of Earthing Conductor: The alignment of the earth mat conductor can be changed by forming U – loops in case it fouls with equipment / structure foundations. The average spacing for East - West rows and for North - South rows of the earth mat shall, however, be kept as near as possible to the spacing indicated in the earth mat design. Earthing conductors in the switchyard area shall be buried at least 600 mm below finished ground level unless stated otherwise. Earthing conductor around any building shall be buried in earth at a minimum distance of 1500 mm from the outer boundary of the building. In case high temperature is encountered at any location, the earthing conductor shall be laid at a minimum distance of 1500 mm away from such location. Earthing conductors, if embedded in the concrete, shall have approximately 50 mm concrete cover. Earthing conductors laid in cable trenches, ladder columns, beams, walls, etc. shall be supported by suitable welding / cleating at intervals of 750 mm. Wherever earthing conductors pass through walls, floors, etc., galvanized iron sleeves shall be provided for the passage of the conductor and both ends of the sleeve shall be sealed to prevent the passage of water through the sleeves. The earthing conductors shall be clamped with the equipment support structures at 1000 mm interval. Transformer / Railway tracks within the switchyard area shall be earthed at a spacing of 30 meters and also at both ends. Flexible earthing connectors shall be provided for the moving parts of equipments such as earthing switches and operating handles of isolators, etc. All lighting panels, lighting fixtures, junction boxes, receptacles, conduits, etc. shall be earthed.

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Earthing

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Earthing risers shall be run from the peaks of structures to the main earth mesh. The earthing bonds of the earth wire tension hardware shall be connected at the top of this earthing riser with bolts and nuts. Bending of earthing rod and flat shall preferably be done by gas heating. Fencing should be separately earthed. Independent earthing conductor for earthing of fencing, buried at a depth of 600 mm, shall be provided 2 metres outside the switchyard fence. All the gates and every alternate post of the fence shall be connected to this earthing conductor at the corners and at every 20 metres. EARTH ELECTRODES: The length of earth electrodes shall not be less than 3250 mm and shall be of one piece. Except where rock is encountered, rods shall be driven to a depth of at least 3000 mm. Where rock is encountered at a depth of less than 3600 mm, the electrodes can be buried inclined to the vertical at an angle not more than 30° from the vertical. In all other cases, drilling shall be done for providing the pit for the electrode. To reduce the depth of burial of an electrode in case of rocky soil without increasing the resistance, a number of rods can be connected together in parallel. The resistance in this case is practically proportional to the reciprocal of the number of electrodes used so long as each is situated outside the resistance area of the other. The distance between two electrodes in such a case shall preferably be not less than twice the length of the electrode. JOINTS: Minimum joints shall be made in the earth mat conductor as well as in preparing the risers. All joints in the steel earthing system, except those where earth mat may have to be separated from equipment, etc. for testing, shall be made by electric arc welding. Welded surfaces should be painted with bitumen compound and afterwards coated with bitumen tape to protect them from rusting and corrosion. Joints in the earthing conductor between the switchgear units and such other points which may be required to be subsequently opened for testing should be bolted type. The bolted connections, after being checked and tested, shall be painted with anticorrosive paint / compound. These joints should be accessible and frequently supervised. Earthing connections with equipment earthing pads shall be bolted type. Contact surfaces shall be free from scale, paint, enamel, grease, rust or dirt. Steel to copper connections shall be first bolted, then brazed and shall be coated with bitumen tape to moisture ingression. All welded joints shall be allowed to cool down gradually to atmospheric temperature. Artificial cooling should not be used. The entire surface of the earth mat is to be covered with 100 mm layer gravel extended one meter beyond the periphery of earth mat. The layer of the gravel may be protected by providing suitable brick / stone lining, wherever required.

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The resistance in this case is practically proportional to the reciprocal of the number of electrodes used.3. Place the electrode in the augured hole such that the top of the electrode is 0.3. Earth Electrode in Loose / Sandy Soil: Excavate a pit approximately1 M.2 2.4 2.4. a number of rods are connected together in parallel. Earth Electrode in Rocky Soil: Where rock is encountered at a depth of less than 3600 mm below the foundation level.3 Last Updated : 31-1-2008 .106 Construction Manual for Sub Stations 2. Place the earth electrode in the excavated pit and drive it in the ground with a sledgehammer such that the top of the electrode is 0.25 metres of the electrode above the ground for connecting it to the earth mat rods.3. excavate a trench which is inclined to the vertical at an angle not more than 30° from the vertical. electrodes. For example. The distance between two electrodes in such a case shall preferably be not less than twice the length of the electrode. The distance between any two electrodes in the example above shall not be less than 2000 mm.25 metres for each length.4. Earth Electrode in Hard Soil: Excavate a pit approximately1 M. x 1 M up to 0.55 meter below the foundation top level. prepare one end as spike for placing / driving into the ground.00 metres plus 0.55 metre below the foundation top level.1 2. the total length of such electrodes should be equal to 3. if required. 2. A sketch showing this type of arrangement is given below.2 2. shall be welded together.2 2. Backfill the excavation and compact the soil after completion of the work. Augur a hole in the ground to a depth of 3 metres. To reduce the depth of excavation and burial of an electrode in case of rocky soil without increasing the resistance.6 metre depth. each of length 1000 mm (3000 ÷ 4 = 750 mm + 250 mm).2. up to 0.2.3 2. This will leave 0.1 2.4.2 2.6 metre depth.1 2. x 1 M. Rod of the applicable diameter to approximate lengths of 3. Hence. if the depth of excavation is reduced to 1350 mm (600 mm below ground level + 750 mm electrode depth).0 PLACING OF EARTH ELECTRODES: (See Annexure – B: (I) EARTH ELECTRODE) Cut M.3. carry out drilling of the rocky soil for providing the pit for the electrode.25 meters (or more if full length of rod is more) and.1 2. then 4 nos. In all other cases.3 2. S.4 2.

Rod of 25 mm diameter. Rods together and weld them on both sides.S. S. A typical joint is shown in Annexure – B. ROD AT EARTH ELECTRODE AND AT MESH CROSSINGS.8 2. LAYING OF EARTH MAT: Excavate trenches along the specified alignments to a depth of 0.S.9 3. increase the depth of excavation so that it can be laid 300 mm below the road or at a greater depth to suit the site conditions.0 3.1 3.6 3.S. Lay the M. S. ROD TO M.1 3. apply bituminous compound to the hot joints.S.S. and weld these pieces on the rods. ROD TO M. S. S. underground service ducts. S. Fabricate four cleats in the shape of M. place two pieces of M. (II): JOINT OF M.S. A typical joint is shown in Annexure – B. Flat of size to be used for earthing risers and of length equal to 10 times the diameter of the M.4 3. First weld these together at the crossing point. Angles from M. Rods crossing each other.80 meter below the foundation top level.2 Last Updated : 31-1-2008 .6. Weld these at all the corners of the joint. Rods of the electrode and the earth mat together. (II): JOINT OF M. or a combination of bentonite and black cotton soil in the ratio of 1:6. etc. 100 mm in case of M. increase the depth of excavation so that it can be laid at a minimum depth of 300 mm below them.7. Angles from M.3 3. (III): JOINT OF M.S.5 3. Cross Joints of M.7 2. After welding. Rod.6.1 3.2 3. ROD AT EARTH ELECTRODE AND AT MESH CROSSINGS. Flat of size to be used for earthing risers and of length equal to 10 times the diameter of the M. pipes.. S. Rods in the Earth Mat: Place the rods so that they overlap each other by 4 times their diameter.g. S.6 2.3 3.2 3. uniformly increase the depth of excavation in the higher level from a distance of 5 metres from the lower level so as to attain the required depth of excavation in the lower level. ROD TO M. Thereafter. S. S.5 For connecting the electrode to the earth mat. S. Straight Joints of M.6. Flat of size to be used for earthing risers and length 4 times the diameter of the rods on both sides of this joint. Weld these at all the corners of the joint.7 3. and cover the joints with bitumen impregnated tape. S. Rod in the excavated trenches. clamp / hold the M. In case of rocky soil. A typical joint is shown in Annexure – B. Wherever the earth mat is to cross cable trenches. apply bituminous compound to the hot joints. 2. S. First weld these together at the crossing point. transformer tracks. Rods in the Earth Mat: Clamp / hold together the two M. Backfill the excavation and compact the soil after completion of the work. After welding. e. Fabricate four cleats in the shape of M.Earthing 107 2. the backfilling can also be done with Bentonite. ROD IN EARTH MAT. to reduce the resistance to earth. Clamp / hold these two lengths of M.7. Wherever the earth mat is to cross a road. and cover the joints with bitumen impregnated tape. Rod.. S. Where different ground levels are provided in the switchyard.

7 4. flat riser from the equipment / structure / peak of the structure to the rod of the earth mesh in the excavated trench and then connect it to the equipment or structures or structure peak. After welding. First weld these together at the crossing point. Cut M. FLAT TO M. S. A typical joint is shown in Annexure – B.3 After welding. S.3 3. Rod and Earth Electrode: Clamp / hold together the M. cut two pieces of M. S. After welding. and cover the joints with bitumen impregnated tape. FLAT TO M.8 3.S.1 3. Angle 50 x 50 x 6 mm of length equal to the width of the M.S. Lay the prepared M. S. Flat of the required length and form / bend it.6 4. Flat.3 4. Clamp the earthing risers with the equipment support structures at 1000 mm intervals. drill necessary holes in the riser and fix it with bolts & nuts. For welded type fitting. The shape of the risers should be same / similar for the same type of equipment / structure. Fabricate two cleats in the shape of M. 3. A typical joint is shown in Annexure – B.8. For bolted type fitting. and cover the joints with bitumen impregnated tape. Weld the two sides of the joint as well as the part between the flats on the top surface. S.S. Alternatively.80 meter below the foundation top level. Weld the M. (VI) JOINT OF M. S. S. Flat should overlap each other by twice the width of the M.S. Joint of M. In case joints are required to increase the length of the M. weld a length equal to at least twice the width of the M. Flat risers.2 4. the two lengths of the M.7. by heating if required. The depth shall be 0. apply bituminous compound to the hot joints.9 4. Backfill the excavation and compact the soil after completion of the work.108 Construction Manual for Sub Stations 3. Flat. Flat 50 × 6 mm into a stirrup (as shown in the drawing) and place on the joint of the rod and flat. Flat below the rod.8 Last Updated : 31-1-2008 . clamp / hold them together.1 4.0 4.S. Flat riser to the rod of the earth mat after fitting / welding it to the equipment / structure / structure peak. Flat of size to be used for earthing risers and of length equal to 10 times the diameter of the M.4 4. ROD TO M. Flat and place these on both sides of the joint of the rod and flat. PREPARATION AND FITTING OF RISERS: Excavate trench from the equipment / structure foundation to the nearest rod of the earth mat. to form a smooth and regular shape to match with the shape / form of the equipment / structures / foundation. S. flats one above the other as above.S. Rod. A typical joint is shown in Annexure – B. S. ROD AT EARTH ELECTRODE. Place the M. The fitting to the equipment / structure may be bolted type (earthing terminal / pad of the equipment) or welded type (structure). After placing the M. S. S. Backfill the excavation and compact the soil after completion of the work.2 3. S. Angles from M. FLAT. S. clamp / hold them together to provide good surface contact. S. Weld these at the joint.S.8. apply bituminous compound to the hot joints. apply bituminous compound to the hot joints and cover the joints with bitumen impregnated tape.5 4.8. (V): JOINT OF M. Weld these to both the rod and the flat. Then form a piece of M. S. and weld on both sides of the rod. Rod and the earth electrode. (IV): JOINT OF M. S. ROD OF EARTH MAT.

10 Last Updated : 31-1-2008 .9 Apply red oxide paint and then green enamel paint on the portion of the risers above ground level.Earthing 109 4. 4. A drawing showing the typical arrangement for earthing of equipment and its structure is given at Annexure – C.

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Earthing 111 ANNEXURE – B Last Updated : 31-1-2008 .

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116 Construction Manual for Sub Stations ANNEXURE – C Last Updated : 31-1-2008 .

c) Marshalling Kiosk to Marshalling Kiosk. The cable laying schedule should then be prepared so that maximum length of the cable in a drum can be utilized.5 Where ‘D’ is overall diameter of the cable. For longer lengths. 1. The drums may be rolled for short distances provided they are rolled slowly and in the direction marked on the drum. leaving minimum scrap lengths.2 1. d) Equipment to Equipment in switchyard. handled and stored properly. Cable drums shall be unloaded.4 2.No.1 2. 2.3 1. small lengths can be unwound from the drum.5 Last Updated : 31-1-2008 . etc. 2. The required lengths of cables are laid between the following equipments: a) C&R Panels in Control Room to Marshalling Kiosk. b) Marshalling Kiosk to Equipment. Type of cable Power cable Control cable Minimum bending radius 12 D 10 D 1. Pulling out of cables from stationary drums shall not be permitted.3 2.2 2. When the cable is to be taken from drums. Cables shall not be bent below the minimum permissible limits given below: S. The cable shall be laid in a manner so that there are no scratches or damages caused to the cable due to rubbing on the sides of the drum.4 1. In the absence of any indication. the drums may be rolled in the same direction as it was rolled during winding. the number of cables of each size and their lengths shall be assessed.CHAPTER – 16 CABLE LAYING AND WIRING 1. The cables are cut after taking into account the length required for connecting to the farthest terminals of the terminal block in the & Relay Panel / MK / equipment at both the ends.0 2.1 GENERAL INSTRUCTIONS: Prior to laying of cables. place the cable drum on a turn table or jack up the drum on a suitable size of steel shaft. Rolling of drums shall be avoided as far as possible. e) C&R Panel to C&R Panel / other panels in Control room.0 1. Small cut lengths of cable left after laying long lengths can be used for bus wiring and looping.6 Cut lengths of cable which are available as surplus / left over material from other works should preferably be used first. 1. PAYING OUT OF CABLES: Handle the cable with care to prevent forming of kinks and damage to the insulation of the cable.

3.2 4. 3.3 4. wherever required for cable identification.2 The cables are securely fixed on the racks in the cable trenches.C. Power and control cables shall be laid in separate tiers. The width may be increased in case a number of cables are to be laid. and a cable number are punched on the cable tag / marking strip. Cable tags shall also be provided inside the switchgear.2 4.5 4.1 3. Cover the cable with bricks and backfill the trench with the excavated sand.118 Construction Manual for Sub Stations 3. Generally Cable size. The markers shall project 150 mm above ground and shall be placed at intervals of 30 meters and at every change in direction.6.1 4.3 4. supply. LAYING OF UNDERGROUND POWER CABLES: Excavate trench of 30 cm width and 75 cm depth along the proposed route / alignment.3.. Cables from CT / CVT / PT. the depth shall be increased such that the bottom of the trench is 40cm below them.3. Compact the sand by ramming.6 4.1 4.6. Rectangular shaped cable tag / marking strip of 1. on both sides of a wall / floor crossing & on each duct / conduit entry for identification of the cable. Location of underground cable joints shall also be indicated with cable marker with an additional inscription "Cable joints".1 LAYING OF CABLES IN TRENCHES: The cables are placed in the racks in cable trenches. The numbering of cables on the tags shall be done as per cable schedule.4 4.3. Cover the bottom of the trench with a layer of sand 25 cm thick. etc.0 mm thick aluminum with the description punched on it shall be securely attached to the cable by not less that two turns of 20 SWG GI wire. Marking and Tagging: Directly buried underground cables shall be clearly identified with cable marker made of iron plate. Lay the cable in the excavated trench.3 Last Updated : 31-1-2008 . The order of placing cables (other than those directly buried) in cable trenches shall be as follows: a) b) c) Bottom tiers: Middle tiers: Upper most tiers: Power Cables / Cables having A. At crossings of cable trenches / roads / transformer tracks / pipes / earth mat conductor.6.. Cables having D.0 4. Marking and Tagging: Provide cable tag / marking strip on all cables at both ends (just before entry into the equipment enclosure).0 3.2 3. supply. etc. C. control and relay panels.3 3. identification of initial point and terminating end of equipment / Panel. They shall also be located on both sides of road and drain crossings. Particular care shall be taken when cables are laid in vertical & inclined cable trenches / galleries / vaults or supports. Secure the cables on the supports above ground level.

3 6.0 6. strip off the outer and inner insulation sheaths of the cable. etc.2. Connect the wire to its terminal on the terminal block and tighten to ensure secure and reliable connection. as required) of appropriate size on the wire. Fit the gland nut in the cable. Bend the armouring to fit the gland.2 5.6 6. etc.4 6. Seal all unused openings for cables in the cable gland plate to prevent entry of vermin and dust. Cut each wire at the length required for terminating it on the terminal block.2 6. shall be neatly bunched. Fix the cable gland on the cable end and then fix the cable gland on the gland plate of the equipment / panel. clamped and tied with nylon strap or PVC perforated strap to keep them in position. equipments. for fixing the cables. Strip off the insulation of each core of the cable which is to be connected.2. In panels in which a large number of cables are terminated.5 6.1 6. Crimp the termination end / thimble / lug (pin or ring type. 5.0 5. Mark each core of the cable at both ends with a tag / ferrule as per cable schedule / schematic drawing. For unarmoured cable.2 5.3 6. WIRE TERMINATION: Identify each cores of the cable either by its physical location / marking / numbering or by testing continuity from both ends. therefore.1 CABLE TERMINATION: Drill the required holes in the gland plates of the panels / equipment. For armoured cables. the complete cable number may also be included in the tag / ferrule on each core. Mark all the spare cores of the cables with tags / ferrules indicating the cable number. Fit the cable gland on the gland plate of the equipment/ panel. All the wires in the Control & Relay panels. This should be done after proper dressing of the wire in the wiring trough.Control Cable Laying and Wiring 119 5. wire identification may be difficult. Fit the gland nut and tighten. strip off the outer and inner insulation sheaths of the cable.7 Last Updated : 31-1-2008 .1 5. Strip off the insulation of the cable for sufficient length so that any wire of the cable can be terminated at the farthest terminal in the terminal blocks. Cut off the armouring for the stripped off length keeping a small length for fitting in the cable gland.

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0 1.2. The recommended maximum boost charging voltage is 2.2 1. The float voltage (2. whichever is earlier.1 volts per cell. or the capacity of the battery charger. Keep the batteries away from heat sources.30 volts per cell.5 1. the batteries must be given a freshening charge (as per para 3. After a discharge. then a freshening charge (as per para 3. Re .25 1.5 3.5 1.3 Charging Interval (in months) 6. The electrical contacting surfaces should be free from dust. etc.2. sparks. Read “Installation and Operating Instruction Manual” prior to installation of the VRLA batteries. If VRLA batteries are stored for a longer duration at an ambient temperature not exceeding 27ºC.6.25 V) of VRLA Battery Set should be set as per the manufacturer’s recommendations for maximum service life. 1.1 Last Updated : 31-1-2008 . The terminal bolt connections should be tightened to a torque as mentioned in the manufacturer’s erection manual. If the ambient temperature during storage is above 27ºC. The table below shows the charging interval at the various elevated temperature before which a freshening charge is to be given.6 1.17 BATTERY SETS (VALVE REGULATED LEAD ACID / VRLA) 1.23 V / 2. Ambient Temperature in ºC 32 37 42 47 52 1.0 2. The charging current should be limited to a maximum of 20 % of the 10 hour capacity of the Battery Set.2.0) at shorter intervals. the batteries should be recharged immediately.CHAPTER .4 1.1 1.1 GENERAL INSTRUCTIONS: Battery charging and discharging and all activities related to the erection and installation of the Battery Set should be carried out strictly as per the recommendations / directions / procedure given in the Erection & Installation Manual of the Battery Manufacturer. STORAGE: The VRLA batteries are supplied in the factory charged condition and can be stored up to a maximum of 6 months at an ambient temperature not exceeding 27ºC without requiring a freshening charge.3 The VRLA batteries should be charged with constant potential chargers.0 4. fire.torque the connections once every six months.0) should be given once in 6 months or when the Open Circuit Voltage (OCV) drops to 2. Clean the batteries as and when dust accumulates. etc.2 1. DO’S & DON’TS: DO’S: a) b) c) d) e) f) g) h) Store the batteries in covered area.

Do not tamper with safety valves. etc. Erect the modules containing the cells on the mounting frame / stand as per the Manufacturer's manual and erection drawings.).2 DON’TS: a) b) c) d) e) f) g) h) i) j) Do not store the batteries in places which are exposed to direct sunlight. FRESHENING CHARGE: Give a freshening charge to the Battery Set by gradually increasing the voltage. and install the mounting frame / stand in the battery room.4 2. as per manufacturer’s general arrangement drawings. Do not use abrasive brush or steel brush to clean the electrical contacting surfaces. Make inter cell connections.7 A minimum free space of one meter should be provided on all sides of the Battery Set for ease in assembly and carrying out periodic checks. 1. Connect the positive terminal of the 54th cell (for 110 V Battery Set) / 108th cell (for 220 V Battery Set) and the negative terminal of the 1st cell of the Battery Set to the positive and negative terminals of the battery charger respectively. Do not allow any metal objects to rest on the battery or fall across the battery terminals. Do not over tighten the terminal bolts.122 Construction Manual for Sub Stations 1. The voltage should not be allowed to exceed 2.1 2. top cover and instruction labels. Crimp on terminal lugs / thimbles of suitable size at both the ends. Fit battery identification label (serial no. Do not mix ordinary conventional lead acid batteries with maintenance free VRLA batteries. front cover.0 2.6 2. Tighten the terminals and inter cell connectors to a torque as mentioned in the manufacturer’s erection manual. Do not install the Battery Set in air tight enclosure.30 volts / cell. Also connect the positive terminal of the 48th cell (for 110 V Battery Set) / 96th cell (for 220 V Battery Set) to the battery tap terminal of the battery charger.1 Last Updated : 31-1-2008 . Do not mix the batteries of different capacities or makes. as supplied. on the cells. No such battery tap is provided in 48 V Battery Set.3 2. Clean terminal surfaces of the cells with clean dry cotton cloth. dust storm. ERECTION: Assemble.7 3. Do not attempt to add water or acid in the batteries. rain.6.0 3. Lay the cables for connecting the Battery Set to the battery charger. using the inter cell connectors after applying a thin layer of petroleum jelly on the bolts (only those supplied with the Battery Set should be used). Strip off the insulation of the cable ends and of the wires. if required. The current should not be allowed to exceed 20 % of the 10 hour capacity of the Battery Set or the capacity of the battery charger. Do not attempt to dismantle the battery. 2.1 2.5 2.2 2.

the cell voltages shall not be les than the following values. C. ‘C27’ is the Capacity of the Battery Set at 27 Deg. a) Maintain the discharge current within ± 1 percent of the specified rate of discharge.30 12 hrs. 2. b) Record the voltmeter and ammeter readings every 5 minutes for the first 15 minutes. This capacity is corrected to 27 Deg. 100 where ‘t’ is the average ambient temperature of the battery room. the matter should be referred to the manufacturer. This shall be taken as the period of discharge. at a current equal to 10 % of its rated ampere hour capacity till the voltage of any one cell reaches 1.0 4. Time Cell Voltage 2.28 12 hrs. Finally charge the Battery Set as per para 5. and ‘Ct’ is the measured Capacity of the Battery Set at ‘t’ Deg.3 During the above discharge test. If this is not achieved.2 4. 4. 4. Below 15 °C 2. Either of the two options given in the table below can be adopted.. are given below.75 volts or the total battery close circuit voltage reaches 1. 4. whichever is earlier.30 24 hrs.6 below. with reference to the ambient temperature. Discharge the Battery Set at its 10 hour rate.25 30 hrs.0 and put it in operation in the floating mode as per para 7.1 DISCHARGE / CAPACITY TEST: The Battery Set shall be discharged after keeping it open circuit for not less than 2 hours and not more 24 hours from the completion of full charge.4 The capacity of the Battery Set is obtained by multiplying the discharge current in amperes by the time in hours as observed above.23 30 hrs.0. and thereafter every 15 minutes up to the end voltage. 2.75 Volts 4. Option Temperature Cell Voltage 1. The temperature of the battery terminal shall be measured as it will be almost the same as the electrolyte. C.25 60 hrs. a) After six minutes from the start of discharge: b) After six hours of discharge: c) At ten hours of discharge: 1. d) The average temperature of the electrolyte during discharge shall be the average of the temperature readings noted at hourly intervals during discharge.2 The duration of the freshening charge and the voltage at which the Battery Set is to be charged. The minimum acceptable capacity of the Battery Set (corrected to 27°C) which is to be achieved during the above discharge test is 85 % of the rated capacity.98 Volts 1. C by the formula: C27 = Ct + Ct × 0.6 Last Updated : 31-1-2008 . Time Above 32 °C 2. equalize the voltage of all the cells as given at para 4. c) Note the time in hours elapsing between the beginning and end of the discharge.e.75 × n (where n is the number of cells in the Battery Set). i.43 × ( 27 – t ) .5 If 100% or more capacity is achieved at any time during the above discharge test. 4. 2.Battery Sets (Valve Regulated Lead Acid / VRLA) 123 3. 15 – 32 °C 2.92 Volts 1.

1. If 100 % capacity of the Battery Set is not achieved even after these five discharges. the Battery Set should not be accepted and the matter should be referred to the manufacturer. 4.9 5.0 6.1 5.2 6. If this discharge is a capacity test.2. Measure the voltages of all the cells of the Battery Set and record for future reference.3 and take necessary action as required.1 6. note the time in hours elapsing from the beginning to the end of the discharge.75 V until the voltage of all the cells reaches 1. switch off the boost charger.2 8. Switch on the float charger after setting its output voltage as per manufacturer’s recommendations.2. Calculate the capacity as given at para 4. then charge the Battery set as per para 5. CHARGING / RECHARGING: Immediately after the discharging is completed. DISCHARGING: Discharging of the Battery Set is to be done as per procedure given at paras 4.7 If 85% or more capacity is achieved during the above discharge test.0 5.8 Charge and discharge the Battery Set until 100 % capacity is achieved. then equalize the voltage of all the cells as given below.1 and 4. After the Battery Set has been fully charged as per para 5.75 V. If the Battery set has achieved 100% capacity. The voltage should not be allowed to exceed 2.2 7. 4. Keep bypassing the cells that reach 1.1 7. the Battery Set should be charged by gradually increasing the voltage. The current should not be allowed to exceed 20% of the 10 hour capacity of the Battery Set or the capacity of the battery charger. Continue discharging the Battery Set at its 10 hour rate.124 Construction Manual for Sub Stations 4. If 100% capacity is achieved within another four discharges. Continue the charging till the charging current reduces to a negligible value.75V. a) b) c) Bypass the cell that has first reached 1. finally charge the Battery Set and put it in operation in the floating mode.0 Last Updated : 31-1-2008 .30 volts / cell.

1. 1.0 1. 4.CHAPTER . Strip off the insulation of the cable ends and of the wires.2 2. S. 2. 220 kV side Annunciation. Crimp on terminal lugs / thimbles of suitable size at both the ends.18 DC PANELS 1.4 2. 10. 8. Then connect the cables to the positive and the negative terminals of the battery charger. 9. Crimp on terminal lugs / thimbles of suitable size at both the ends.1 GENERAL INSTRUCTIONS: The DC supply to the various circuits / panels at 220 kV and 132 kV sub stations are connected from independent MCB’s. Measure insulation resistance of panel wiring with 500 V Megger before connecting any cable. Connect the cable at both the ends.2 220 kV GSS 220 kV C & R Panels 132 kV C & R Panels 33 kV C & R Panels Annunciation. 3. 132 kV side Annunciation. The DC supply to the panels / schemes is connected as per the DC supply scheme. 5. two independent Battery Sets and DC Panels are provided.3 2. 33 kV side LT & RTCC Panels PLCC / SLDC Emergency Light Bus Bar & LBB Protection Spare 132 kV GSS 132 kV C & R Panels 33 kV C & R Panels Annunciation. 33 kV side LT & RTCC Panels PLCC / SLDC Emergency Light Spare At 400 kV sub stations. Connect one end of the individual cables to the terminals in the terminal blocks corresponding to the designated MCB’s in DC Panel. Lay the cables from the DC Panel to the respective C & R Panels / equipment.5 2. Place the DC Panel at its designated location in the control room as per layout. First connect the cables to the positive and the negative terminals of the DC Panel. 132 kV side Annunciation. The typical distribution of the MCB’s is as below. 6.8 2. Strip off the insulation of the cable ends and of the wires.1 2. Fix / bolt the DC Panel on the trench provided in the floor of the control room or on the base frame if provided. Lay the cables from the DC Panel to the battery charger.No. Lay the cable from the LT Panel to the DC Panel for AC supply. Strip off the insulation of the cable ends and of the wires. Connect the other end of the cables in the respective C & R panels. 1.3 2. Crimp on terminal lugs / thimbles of suitable size at both the ends.7 2.6 2.9 Last Updated : 31-1-2008 .0 2. 11. 7. ERECTION AND INSTALLATION: Check the DC Panel for any mechanical damage before installation.

etc.3 4. Check the voltage on the voltmeter at the selector switch position “+ ve to – ve”. Identify the polarity (+ve or –ve) which is earthed as given at para 3. Check that DC supply is available at these outgoing terminals.5 3. Trace the fault and rectify the earth fault. The voltages at “+ve to Earth” and “–ve to Earth” positions of selector switch should be equal. Check the operation of the emergency lighting system. The voltmeter should show full DC voltage.8. per cell voltage multiplied by the tapped cell (48th cell of 110 V DC system or 96th cell of 220 V DC system). and rectification if required. Check functioning of space heater and internal illumination circuits. If these are not equal.0 4. Check the voltages on the voltmeter at the different selector switch positions of “+ve to Earth” and “–ve to Earth”. it indicates an earth fault in the negative circuit. Switch ON the boost circuit and switch OFF the float circuit in the battery charger. Check earthing of the DC Panel to the earth mat.1 4.1 3. it indicates an earth fault in the DC system connected at this stage.6 3. Switch off the AC supply to the DC Panel.4 3.. If the “–ve to Earth” voltage is less than the “+ve to Earth” voltage. 3.3 3. Check the working of the DC earth fault relay. If the relay operates.e.2 PRE – COMMISSIONING CHECKS: Check tightening of all terminal connections.7 and para 3. Check that AC supply is available at the designated outgoing terminals for the emergency lighting circuit. Switch on the AC supply to the DC Panel. If the “+ve to Earth” voltage is less than the “–ve to Earth” voltage. “DC earth fault”. by following the steps given at para 3.8 3. POST – COMMISSIONING TESTS: Switch on the individual MCB’s and check the voltage and polarity of DC supply at the corresponding outgoing terminals. as provided in the DC Panel.8 after switching on each MCB. Check the annunciations such as “DC supply fail”. Set it at the minimum setting.7 3. i. it indicates an earth fault in the DC system connected at this stage.0 3.9 4. it indicates an earth fault in the positive circuit. Carry out checking of DC earth fault.126 Construction Manual for Sub Stations 3.4 Last Updated : 31-1-2008 .2 4. Check the availability of battery tap voltage. The voltage on the voltmeter should correspond to the tapping voltage. Keep the voltmeter selector switch in the position “+ve to –ve”. Check the voltage and polarity of the DC supply at the terminals of the incoming cable from battery charger.

PRE – COMMISSIONING TESTS: Connect only the AC supply cable from the LT Panel. Put the switch in Auto position.3 4. Check the annunciations such as “AC supply fail”.0 2.1 3. Calibrate the DC voltmeter.0 1.5 4.8 4. During battery boost charging and in float operation.9 Last Updated : 31-1-2008 .4 2. Raise the voltage manually to the required output value and check the voltage and polarity on the load and battery terminals.2 1. Switch on the Boost Charger.2 4. The cables to the Battery Set and the DC Panel should not be connected. Adjust the voltage setting if required. Lower the voltage manually to check operation of the control circuit. The output voltage should decrease to the set value. as provided. “DC earth fault”.2 2. Place the temperature sensor in the battery room and connect it to the Battery Charger.1 4.19 BATTERY CHARGERS 1.1 GENERAL INSTRUCTIONS: Maintain a minimum spacing of 15 cm between the Battery Charger and other panels on both the sides for proper ventilation.CHAPTER .3 3.0 4. Repeat the above test by increasing the voltage. ALWAYS KEEP THE FLOAT CHARGER ON EVEN WHEN BOOST CHARGING THE BATTERY SET IN SERVICE. “Fuse Failure”. PRE – COMMISSIONING CHECKS: Check tightening of all terminal connections. it should be ensured that the rating of the relevant section is not exceeded. 1. Keep the Auto – Manual switch in Auto position. Put the switch in the Manual position and lower the voltage.6 4. Switch on the AC supply and check the voltages on the terminals of the incoming cable. ERECTION AND INSTALLATION: Check the Battery Charger for any mechanical damage before installation.4 4.3 1.0 3. The output voltage should increase to the set value. Set the output voltage to the required value. Check earthing of the Battery Charger to the earth mat. Fix / bolt the Battery Charger on the trench provided in the floor of the control room.2 4. Place the Battery Charger at its designated location in the control room as per layout. etc. Switch on the Float Charger.7 4. Switch off the Float Charger.1 2. Keep the Boost Charger voltage selecting taps (Coarse and Fine) / voltage setting at the minimum position. Keep the Auto – Manual switch in Manual position.

11 4. Raise the voltage manually. The output ammeter will show load current when the output voltage exceeds the Battery voltage. Keep the Float Charger Auto – Manual switch in Manual position. When the load current exceeds the setting of the current limiting circuit. Raise the voltage. Keep the Boost Charger voltage selecting taps (Coarse and Fine) / voltage setting at the minimum position. If this does not happen. The float output ammeter will show load current when the float output voltage exceeds the Battery voltage. After connecting load to the Battery set. put the Auto – Manual switch in Manual position and decrease the output voltage. Put the Keyed Push Button (Boost as Float) in the ON position. switch off the Float Charger (with the Boost Charger off) and check that the full Battery voltage is available on the DC Panel and feeding to the load. Switch on the Boost Charger. Set the voltage to the rated value.3 5. The float output ammeter will show load current when the output voltage exceeds the Battery voltage.1 5. It should also show the Tap voltage in Battery Tap position. Check that the charge / discharge ammeter shows current in the charge direction.6 Last Updated : 31-1-2008 . Put the Float Charger Auto – Manual switch in Auto Position. Switch on the Float Charger.128 Construction Manual for Sub Stations 4.0 5. The charge / discharge ammeter on the Battery Charger should show the current on the discharge side. Connect the cables to the Battery Set and the DC Panel.10 Check the voltage and polarity on the battery terminals.13 5. the float output voltage and current should automatically decrease. Reduce the voltage.12 4. POST – COMMISSIONING CHECKS: The voltmeter should show the Battery voltage in the Battery position.2 5. Return the voltage selecting taps (Coarse and Fine) / voltage setting to the minimum position. Switch off the Boost Charger. 4.5 5. Raise the voltage to the maximum output value and check the voltage on the battery terminals. Adjust the setting of the output current limiting circuit so that the output current does not exceed the rating of the Float Charger. Switch off the Float Charger. The float output current will start increasing. Switch off the Boost Charger.4 5. Check that the rated voltage is available on the load terminals. Check that the charge / discharge ammeter also shows current in the charge direction.

3 2.2 1. integrating meters. for conformity of their characteristics to the specifications and to the technical information / details / particulars intimated by the manufacturer. Event Loggers.1 GENERAL INSTRUCTIONS: Check and ensure that the Control & Relay Panels being installed are meeting the requirements of DC control voltage (110V or 220V) and CT secondary rating (1A or 5A). Also fit the covers for the corridor portion. ERECTION AND INSTALLATION: Place the panels at their designated locations on the trenches in the Control Room as per layout. There shall be no gap between panels which are placed adjacent to each other.CHAPTER . transducers. protection schemes. Level the panels and check their verticality.0 3.5 2. PRE – COMMISSIONING TESTS: Arrange for testing. In the case of Duplex type of panels.0 2. Check that there is no physical damage to the relays and other equipment installed in the C&R Panel.20 CONTROL & RELAY PANELS 1. by the Protection wing. indicating meters.1 4. by the Protection wing.1 2. ICT’s. Connect the Bus wiring / interconnecting wiring between the control & relay panels of the Duplex type.3 3.4 4. for their 1. transducers. these shall be bolted together.1 3. etc. of individual relays. PRE – COMMISSIONING CHECKS: Check the tightness of all terminal connections. S. Disturbance Recorders. etc.4 2.2 Last Updated : 31-1-2008 .3 2. etc. integrating meters. indicating meters. Check earthing of the panels & its connection to the earth mat.6 3. LBB Protection schemes.0 4. ICT’s. Bus Bar Protection schemes. Where a number of panels are to be placed adjacent to each other to form a Board or where a panel is to be placed adjacent to an existing Panel / Board. Also connect the similar wiring between control panel to control panel and / or relay panel to relay panel where a Board formation is made or where panels are connected to an existing Board / panel as per their relevant schematic drawings. as well as special schemes / equipment for 400 kV GSS should be tested / got tested as per their schematic diagrams. of individual relays. protection schemes. Fix or bolt the panels (as per requirement of installation of the panels) on the channel / M. Arrange for testing and verification. Check the availability of DC supply and AC supply in the Control & Relay Panels. Angle fitted on the top of the walls of the trench or on the base frame. as provided. Check the polarity of DC supply in the Control & Relay Panel. in the Control Room.2 3.0 1. connect the control panel to the relay panel across the corridor using the fittings provided with the panels.2 2.

and their closing interlocks.6 Arrange for testing. Alarms provided in circuit breakers 6. Operation of 1. 4. Trip protections such as Buchholz.8 4. Trip protections such as differential. of stability of protection schemes such as differential protection scheme for transformers. as provided in the scheme logic. Test the annunciation scheme by actuating individual alarms from the initiating equipment such as relays. provided on transformers 3. Lockouts provided in circuit breakers Check Points Alarm Operation Tripping of annunciation of Master HV & LV Trip Relay CB’s Alarm annunciation 4. Give the carrier send signal from the Relay Panel and verify that the carrier signal is received back in the Relay Panel.3 4. low oil level. The actual tripping of the circuit breakers should be checked only two or three times with the operation of the Master Trip Relay. provided on transformers 2.1 4.8. and making necessary changes in the settings if and as required.7 4. by the Protection wing. etc. 4. Put the PLCC equipment on local loop test. 4.3 Last Updated : 31-1-2008 . circuit breakers.2 4. transformer.130 Construction Manual for Sub Stations performance at the applied voltage / current / operating supply and at the settings selected for their service conditions. protection schemes.8. Put the PLCC equipment in the normal mode at both the ends. The protection scheme logics and annunciation schemes are generally checked as below. etc. Test the tripping & inter-tripping of associated circuit breakers on the operation of relays / protection schemes. provided in C&R Panels for feeders & other circuits 5. over current. Alarm protections such as high oil & winding temperature. Testing of Carrier Trip Commands: These tests should be carried out for all the codes. over current. Trip protections such as distance. etc.4 Test the protection scheme logics for alarm and trip as per approved schematic drawings. OSR. etc. etc.5 Operation of relevant auxiliary relays Operation of relevant auxiliary relays* Alarm Operation Tripping of annunciation of Master HV & LV Trip Relay CB’s Alarm Operation Tripping of annunciation of Master relevant CB Trip Relay Operation of relevant auxiliary relays* Operation of relevant auxiliary relays* Alarm annunciation Alarm Trip circuit CB annunciation faulty operation indication blocked *if provided Note: The operation of the Master Trip Relay should be verified for actuation of all trip protections as above. etc. No. provided in C&R Panels for transformers 4. earth fault. earth fault. etc.8.

Verify that the carrier signal is received in the corresponding Relay Panel at this end. etc.4 Give the carrier send signal from the Relay Panel and verify that the carrier signal is received in the corresponding Relay Panel at the other end. Carrier Received.1 5. etc.6 4. and distance protection schemes. Test the annunciations by actuating individual alarms such as Carrier Fail. 4. as applicable.0 5.13 5. Ask the Engineer at the other end to send the carrier send signal from the Relay Panel at his end. of stability of transformer differential protection on load. from the PLCC equipment. Test the functioning of space heaters and sockets. earth fault.8. Arrange for checking and verification. Verify the operation of equipments from the control switches / push buttons provided for them.7 4. Test the internal illumination system including operation of the door switches.Control and Relay Panels 131 4.9 4.8. Verify indication lamps / semaphores for circuit breaker / isolator status by operating the relevant equipment. Test the tripping of associated circuit breakers once or twice on the receipt of direct trip signals. POST – COMMISSIONING CHECKS: Check phase sequence of the VT supply in the Control & Relay panels. by the Protection wing.10 4.8.4 Last Updated : 31-1-2008 . of directional feature of over current. by the Protection wing. protection schemes. etc. Measure the voltage & current in the relevant circuits.2 5.3 5. Arrange for checking.8. and check their readings in the relays. Verify the interlocks for operation of isolators. meters.12 4.5 4.11 4.

132 Construction Manual for Sub Stations Last Updated : 31-1-2008 .

Measure insulation resistance of panel wiring and the LT Bus Bar (phase to phase and phase to earth) with 500 V Megger before connecting any cable.21 LT PANELS 1.3 2.0 1. 13. Lay the cables from the LT Panel to the respective bay marshalling kiosks / C & R panels / transformer.2 At 400 kV sub stations. 11.No.6 2. 6. Strip off the insulation of the cable ends and of the wires. 12. 3.0 2. 2.4 2. 2. 10. The AC supply to the panels / equipments / kiosks is connected as per the AC supply scheme. Then connect the cables to the LT terminals of the station transformer. 5.1 2. Lay the power cable from the station transformer to the LT Panel. 14. 220 kV GSS Colony Lighting 220 kV CB 132 kV CB 33 kV CB 220 / 132 kV Transformer Battery Charger 220 V Battery Charger 48 V Yard Lighting Control Room Lighting Tube Well Spare Spare C & R Panel DC & RTCC Panels 132 kV GSS Colony Lighting 132 kV CB 33 kV / 11 kV CB Spare Yard Lighting Control Room Lighting 132 / 33 / 11 kV Transformer Tube Well Battery Charger 110 V Battery Charger 48 V Spare Spare C & R Panel DC & RTCC Panels (The supply to Colony Lighting and Tube Well shall be through separate energy meters) 1. 4. First connect the cable to the LT Panel. 7.2 2. ERECTION AND INSTALLATION: Check the LT Panel for any mechanical damage before installation.7 2.5 2. two independent Station Transformers and LT Panels are provided. The typical distribution of the SFU’s is as below. Fix / bolt the LT Panel on the trench provided in the floor of the control room.CHAPTER .8 Last Updated : 31-1-2008 . S. Place the LT Panel at its designated location in the control room as per layout. 8. Crimp on aluminium terminal lugs / thimbles of suitable size at both the ends.1 GENERAL INSTRUCTIONS: The AC supply to the various circuits / panels at 220 kV and 132 kV sub stations are connected from independent switch fuse unit (SFU’s). etc. 1. 9. Strip off the insulation of the power cable ends and of the wires. Crimp on terminal lugs / thimbles of suitable size at both the ends.

Connect the other end of the cables in the respective equipment.3.5 3. then discharge the spring as per instructions given in the manufacturer’s manual.10 3.3. PRE – COMMISSIONING CHECKS: Check tightening of all terminal connections. Check tripping of LT CB from Protection Trip. mechanical latches and stopper(s) as provided. Check operation of anti – pumping / anti – hunting relay by giving continuous closing and tripping signals simultaneously.3.3. Check operation of the outgoing Switch Fuse Units and its locking mechanism. Close and trip the LT CB manually.1 3.5 4. Lubricate all the moving parts and the pins in the operating mechanism. AUTO TRIP and SPRING CHARGED conditions.2 3.7 3. Check lamp indications of the LT CB for CB OPEN. Charge the spring electrically and verify the operation of the limit switch.0 3. The breaker should close and then trip and should not close again. Last Updated : 31-1-2008 . Check rating of fuses in switch fuse units (SFU’s).3. Take all the precautions mentioned in the manufacturer’s manual.4 3. Check the annunciations for protection trip. Strip off the insulation of the cable ends and of the wires. etc.3.134 Construction Manual for Sub Stations 2.6 3.8 3.2 3. as provided.3. Check earthing of the LT Panel to the earth mat.3 3.3.11 3.3.10 3.1 3.3. CLOSED.1 PRE – COMMISSIONING TESTS: Measure IR values with 5 kV Megger between incoming and outgoing terminal of the LT Circuit Breaker when the CB is OFF. If it is not fully discharged.3 3.3. Adjust the setting of the limit switch if required.9 Connect one end of the individual cables to the terminals in the terminal blocks corresponding to the designated switch fuse unit in the LT Panel. Check operation of the LT Circuit Breaker electrically. Crimp on terminal lugs / thimbles of suitable size at both the ends.0 4. Carry out slow mechanical operation (closing and tripping) of Circuit Breaker as per procedure prescribed by the manufacturer. 2. Lay the cable from the DC Panel to the LT Panel for DC supply.9 3. Connect the cable at both the ends.4 3. Manually charge the closing spring and check electrical limit switch. LT Circuit Breaker: ENSURE THAT THE CLOSING SPRING IS FULLY DISCHARGED.

5.0 5. Check functioning of space heater and internal illumination circuits. Switch on the individual switch fuse units and check the voltage of AC supply at the corresponding outgoing terminals.LT Panels 135 4. “Y – B” and “B – R”. Energy Meter. etc. POST – COMMISSIONING TESTS: Energize the station transformer and check the voltage and phase sequence of the AC supply at the terminals of the incoming cable from the station transformer. by the Protection Wing. Check the voltage on the voltmeter at the different positions “R – Y”. Close the doors / openings provided in the LT Panel.5 Last Updated : 31-1-2008 .4 5.2 5. testing of LT Current Transformer.2 Arrange for checking of operation of Over Current and Earth fault relays & their settings. The voltmeter should show voltage corresponding to the voltage of incoming supply.1 5.3 5.

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5 2. DO keep the equipments in dust free environment.8 2. Lay the co – axial cable from LMDU to the Carrier Set.3 2.22 PLCC CARRIER SETS 1. DO ensure that all connections are firmly tight. DO ground the terminal chassis properly. Place the structure / frame near the cable trenches in the PLCC room in such a manner that sufficient space is available for accessing the Carrier sets from the rear for maintenance as well as from the front for setting up test instruments. The work should be done under the supervision of the Work – In – charge / Manufacturer’s Engineer and as per instructions given by him / them. Erect the Carrier sets at their locations on the fabricated structures / frames.0 1. Maintain a minimum spacing of 30 mm between two carrier sets on both the sides for proper ventilation.5 2. Do not disturb the factory settings of the equipment. The structure/ frame should have a height of at least 150 mm from floor level to facilitate cable entry in to the panel. in their designated locations in the Carrier Terminal as per erection manual. DO keep hand set and measuring leads inside the PLCC terminal. Earth the Carrier Set and the structure / frame. ERECTION AND INSTALLATION: Fabricate the structure / frame as per the fixing dimensions of the Carrier sets.1 GENERAL INSTRUCTIONS: Wear grounding straps when handling the modules since they contain CMOS (compound metal oxide semi – conductor) devices which can be damaged by electrostatic discharge. DO’S AND DON’TS: i) ii) iii) iv) v) vi) vii) 1. Check the Carrier sets for any mechanical damage during transportation.3 The erection and installation work should be carried out as per instructions/ procedure given in the Manufacturer’s Installation and Commissioning Manual.7 2. if received separately.9 2.2 1. 1. Insert the modules.4 DO NOT alter user settings unless it is absolutely necessary.10 Last Updated : 31-1-2008 .2 2. 1. DO take all the antistatic precautions.CHAPTER . Then grout the structure / frame.0 2. Level the Carrier Sets and fix them on the structure / frame. DO NOT insert or eject the modules from their location in the shelf when the power supply is ON.6 2.1 2.4 2. Prepare the ends of the co – axial cable and fix the connectors at the ends. Clean the interior of the rack of the Carrier sets with vacuum cleaner. Fit the co – axial cable on the Carrier Set and LMDU.

Carry out setting.6 3.5 Verify the following. 2W & 4W AF levels. Check the functioning of power sockets. a) b) c) d) e) f) g) h) Test tone of 800 Hz / 1000 Hz at the test point.4 3. Any other setting / test as prescribed by the manufacturer.10 4. Check that all the modules are fitted in their correct locations. Check that all the inter – connectors are fitted and properly inserted.3 3.7 3.2 3.8 3.4 4. Output of power amplifier at 125 / 75 Ohm termination.1 PRE – COMMISSIONING CHECKS: Measure the resistance of the earthing connections of the Carrier Sets to the earth mat. All the alarms in all the units. Ensure that the earthing of the HF terminal of the CVT and the LMU / LMDU have been opened. Ensure that the exhaust fan is working. Switch on the Power Supply Unit.3 4.0 4. Measure output voltage at the test points.9 3.1 4. Visually check the cards for any dry solder in the circuit.2 4. a) b) c) d) e) Signaling operation by extending ground. Communication with the remote end operator over service telephone.5 3. Last Updated : 31-1-2008 . Pilot levels at HF co-axial.138 Construction Manual for Sub Stations 3. The earthing connection should have resistance of less than 1. measurement and adjustment of frequency and levels at both ends (transmitted / received) as per commissioning manual of the manufacturer. AGC level.0 3. Loop back status (local loop and remote loop). Check that all strappings and settings of the DIP switches in the modules and on the rear side of the PCB’s are in accordance with the programming table.0 Ohm for safety. PRE – COMMISSIONING TESTS: Connect 48V from DC power source to Carrier set and check the polarity of DC voltage at the terminals. Any other setting / test as prescribed by the manufacturer. etc. IF and RF levels. Check the internal illumination system. Tx & Rx frequencies. Check the tightness of all terminal connections. 3. Switch on the MCB.

Composite loss (attenuation) for HF cable coupling device. or inter – phase R & R and B & B) to determine the optimum coupling mode. i) ii) Open behind the wave trap. Last Updated : 31-1-2008 . End to end return loss of the adopted coupling mode (phase to phase R & B. Grounded behind the wave trap.6 Carry out the following tests on the complete system. refer Chapter 12 on Wave Traps). 4. the same shall be measured for other coupling modes (phase to phase R & Y and Y & B.7 If the end to end return loss for the adopted coupling mode is not satisfactory. or inter – phase Y & Y.PLCC Carrier Sets 139 4. a) b) c) Composite loss and return loss on coupling devices using dummy load. The Wave Traps and the connections to the CVTs should be got changed as per the optimum coupling mode.

140 Construction Manual for Sub Stations Last Updated : 31-1-2008 .

etc.1 3.4 3.2 1. Put the equipment on local loop test. from the Protection Coupler.1 1.3 2. Test Annunciations by actuating individual alarms such as Carrier Fail. Give the trip command from Relay Panels and verify that the trip command is received back in the Relay Panels. Configure the equipment as per programming table. Carrier Received.23 CARRIER PROTECTION COUPLERS 1.2 3.0 2. Check Tx and Rx Trip commands for their proper operation.8 Last Updated : 31-1-2008 .4 3. Clean the Protection Coupler with vacuum cleaner.3 3. Check tightness of all terminal connections. PRE . Test the equipment on local loop test.COMMISSIONING CHECKS: Visual check for any dry solder in the circuit boards.0 3. Fit the Protection Coupler in the PLCC terminal if received separately. 3.3 2. Check that all the inter – connectors are fitted and properly inserted. Make connections from the respective Relay Panels to the MDF (main distribution frame) of the equipment as per scheme.7 3. This should be done for all the codes.2 2.1 2. Verify the transmission and receipt of Tx and Rx commands on all the codes of the Protection Coupler by initiating trip commands from the Relay Panels at both ends.CHAPTER . PRE – COMMISSIONING TESTS: Check the DC voltage and its polarity in the Protection Coupler. Check that all the modules are fitted in their correct locations.5 ERECTION AND INSTALLATION: Check the Carrier Protection Coupler for any mechanical damage before installation. Put the equipment in the normal mode at both ends.6 3.0 1.

142 Construction Manual for Sub Stations Last Updated : 31-1-2008 .

0 3. Again check the various voltages at test points. Grout the structure / frame in the PLCC Room near the cable trenches. The system should work normally.4 1.3 1. Configure the exchange / local numbers / Tie line numbers as per the procedure given in the instruction manual of the manufacturer.8 3. Wire the trunk lines (Tie lines) from the PLCC carrier set to MDF of the exchange.6 2.3 3.CHAPTER .24 PLCC EXCHANGE 1.1 ERECTION AND INSTALLATION: Fabricate the structure / frame as per the dimensions of the PLCC Exchange. PRE – COMMISSIONING CHECKS: Connect 48 V DC Supply to the exchange and ensure correct polarity.6 2.5 2. Verify the alarms provided in the Exchange.7 2.5 1.0 1. Measure various output voltage at the specified test points. The structure should be grouted in such a manner that enough space is available for access to the Exchange from the front for setting up test instrument and from the rear for maintenance. Clean the interior of the PLCC Exchange panel with vacuum cleaner. Switch off the power supply unit and plug in all the cards in to their respective slots. The structure / frame should have a height of at least 75 cm above floor level.2 1. Earth the Exchange and the structure / frame.2 3. Dial up the local as well as the remote end subscribers and verify the satisfactory operation of the Exchange.1 2. 1. Check the PLCC Exchange panel for any mechanical damage before installation. Plug in the power supply module in its respective slot.2 2. Place the Exchange on the structure / frame and fix it after levelling.1 3. Switch on the power supply unit module. PRE – COMMISSIONING TESTS: Connect the local telephone lines to MDF of the Exchange.4 2.4 Last Updated : 31-1-2008 . Switch on the power supply unit.0 2.3 2.

144 Construction Manual for Sub Stations Last Updated : 31-1-2008 .

CHAPTER – 25

COMMISSIONING OF SUB STATION
1.0 1.1 TESTING BY THE PROTECTION WING: All major equipment such as Transformer, Current Transformers, Capacitor Voltage Transformers. All Control & Relay Panels including the protection schemes and relays installed on them. All protection schemes such as Local Breaker Back Up (LBB) Protection and Bus Bar Protection Schemes as provided. Any other protection associated schemes such as carrier aided schemes, etc. as provided. APPROVAL OF THE CHIEF ELECTRICAL INSPECTOR: Before energizing the Sub Station, the approval of the Chief Electrical Inspector of the State Government is required as per Rule 63 of the Indian Electricity Rules, 1956. The application is made in the prescribed questionnaire and submitted along with required drawings and information. The inspection fee, as prescribed from time to time, is to be deposited. A sample format of the proforma for the above application / questionnaire for a 132 kV Sub Station is enclosed in Annexure – A. FINAL CHECKING: Measure the insulation resistance values of each phase to earth of each voltage level after closing all Isolators and Circuit Breakers of that voltage level. The Transformer is not included in this measurement. In case of electromagnetic type of Potential Transformer, open the earthing link / connection of the primary winding. Keep the line Isolators of all the feeders open. The values shall depend on the size of the Sub Station, voltage level and the weather conditions. Open all the Isolators and Circuit Breakers after above checking. CHARGING THE SUB STATION: This is to be done after the approval of the Chief Electrical Inspector has been obtained. The concerning Executive Engineer shall be present at the time of charging the Sub Station who shall ensure that all testing and checking has been done and approval of the relevant authorities has been obtained. Initially, close only those Isolators which are required for charging the main bus. Keep the incoming line Isolator and its earth switch open. Contact the Sub Station at the other end of the incoming line. Give the clearance for charging the line. After the line is charged, close the line Isolator and the line Circuit Breaker. Check the phase to phase and phase to neutral voltages on the Bus voltmeter on the Control Panel.

1.2 1.3

1.4 2.0 2.1

2.2

2.3 2.4

3.0 3.1

3.2 4.0 4.1 4.2

4.3

4.4

4.5 4.6

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Construction Manual for Sub Stations

4.7 4.8

Close the Isolators required for charging the Transformer. Follow the precautions and directions given in para 18.0 of Chapter – 5 for charging the transformer. Before taking load on the Transformer, obtain clearance from the concerning Engineer of the Discom.

4.9

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Commissioning of Sub Station

147

ANNEXURE – A QUESTIONNAIRE UNDER RULE – 63 OF INDIAN ELECTRICITY RULES, 1956 1. Name of Sub Station 2. Operating Voltage of the GSS 3. Type & Height of the structures used 132 kV GSS, _________________ 132 / 33 kV Lattice type steel fabricated structures for bus height of : 132 kV side : 7.5 Mtrs. 33 kV side : 5.5 Mtrs. String of 11 kV B & S type disc insulators, 45 KN and 120 KN E & M Strength for suspension and tension respectively. a) Bus Bar of ACSR Conductor: Name Aluminium Steel Zebra 54/3.18mm 7/3.18mm Panther 21/3.00mm 7/3.00mm b) Earth wire: 7 / 3.15 mm GSS wire 132 / 33 kV, 20 / 25 MVA a) Isolators: 132 kV, 800 Amp. 33 kV, 630 Amp. b) Circuit Breakers: 132 kV SF6 CB, 31.5 kA 33 kV VCB / SF6 CB, 25 kA Station type, Metal oxide, 10 kA ______ ohm – metres.

4. Type of Insulators used

5. Type & Size of Bus Bar conductor and earth wire used.

6. Type and capacity of the transformer 7. Type and capacity of gang operated switches, Fuse, Oil circuit breaker, etc.

8. Type of Lightening Arrestors used. 9. Average value of earth resistance in the region. 10. Details of minimum clearance above ground level.

132 kV side – 4.6 M. 33 kV side – 3.7 M. 11 kV side – 3.7 M. ____ Nos. of earth electrodes of 25 mm dia. M. S. Round. In addition, earth mesh of 25 mm dia. M. S. Round and risers of 50 ×10 mm MS Flat are provided. All equipment are as per relevant ISS / IEC standards & inspected by RVPNL engineers (Type and routine tests) before dispatch from manufacturer’s works.

11. Number of earth electrodes provided for the earthing of sub station.

12. Test certificates of manufacturer for transformer, conductors, Insulators, circuit breakers, etc.

Last Updated : 31-1-2008

EXECUTIVE ENGINEER ( ). Drawing of HT / EHT installations showing the method of construction and layout. _____________________. 14. _______________. etc.: 1) Electrical layout of GSS 2) Test report of Transformer 3) Original challan for payment of inspection fee Last Updated : 31-1-2008 . Rajasthan Rajya Vidyut Prasaran Nigam Ltd. Encl. Actual date of completion of work Electrical layout of sub stations showing EHT / HT installation is enclosed.148 Construction Manual for Sub Stations 13.

6. 2. 9. 8. Erection & Installation Manual for Transformers: M/s BHEL. 295). 3. 13. Draft Manual: Volume II: Sub Stations (1968) of the erstwhile RSEB. 4. Erection & Installation Manual for Battery Set: M/s HBL Nife. Installation and Maintenance of Transformers: Installation. 299). Central Board of Irrigation & Power: Manual on Transformers (Publication no. IS: 10028 (Part II) : 1981 – Indian Standard Code of Practice for Selection. Indian Electricity Rules. 12.BIBLIOGRAPHY 1. Last Updated : 31-1-2008 . Erection & Installation Manual for Battery Set: M/s Amararaja. Central Board of Irrigation & Power: Manual on Sub Station Layout (Publication No. IS 1866 : 2000 – Code of Practice for Electrical Maintenance and Supervision of Mineral Insulating Oil in Equipment. 7. IS 15549 : 2005 – Specification for Stationary Valve Regulated Lead Acid Batteries. 1956. IS 3043 : Indian Standard Code of Practice for Earthing. 5. Erection & Installation Manual for Transformers: M/s TELK. 10. 11. IS 731 : 1971 – Specification for porcelain insulators for overhead power lines with a nominal voltage greater than 1000 V.

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