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

6. 15. Selection of Land Layout Design Safety Clearances Earth Mat Design 5 7 33 35 Section – II: ERECTION. 2.CONTENTS Section – I: SITE SELECTION & SUB STATION DESIGN 1. 10. 7. 4. 25. 5. TESTING AND COMMISSIONING 1. 20. 18. 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 . 3. 17. 12. 21. 22. 16. 9. 8. 23. 14. 11. 3. 4. 2. 19. 24. 13.

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

economically and socially optimal and is the best suited to the requirements. The distance of a Sub Station from an aerodrome should be maintained as per regulations of the aerodrome authority. 1.3 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.1 SELECTION OF SITE: Selection of site for construction of a Grid Sub Station is the first and important activity. skillful observation and handling so that the selected site is technically. The site of the proposed Sub Station should not be in the vicinity of an aerodrome.0 1.0 2. This facilitates reduction in leveling expenditure. As far as possible near a town and away from municipal dumping grounds. burial grounds. Sufficiently away from areas where police and military rifle practices are held.4 1. Far away from obstructions.CHAPTER – 1 SELECTION OF LAND 1. structures. to permit easy and safe approach / termination of high voltage overhead transmission lines. equipments. etc. environmentally. fore-sight. This needs meticulous planning. Above highest flood level (HFL) so that there is no water logging.5 The site should have as far as possible good drinking water supply for the station staff.1 Last Updated : 31-1-2008 . The site should be: a) As near the load centre as possible. Easily accessible to the public road to facilitate transport of material. Approval in writing should be obtained from the aerodrome authority in case the Sub Station is proposed to be located near an aerodrome. Preferably fairly leveled ground. and should have the sufficient area for future extension of the buildings and / or switchyard. The main points to be considered in the selection of site for construction of a Grid Sub Station are given below.2 1. b) As far as possible rectangular or square in shape for ease of proper orientation of bus – bars and feeders. 2. tanneries and other obnoxious areas.

the requirement should be restricted to the limit mentioned in para 2.2 The requirement of land for construction of Sub Station including staff colony is as under: S.2 above. While selecting Government land. the requirement may be made liberally but in other cases. 3. where payment is to be made for the land acquisition.0 Hectare 3.0 Hectare 6.5 Hectare 2.2. 1.No. 2. Last Updated : 31-1-2008 .6 Construction Manual for Sub Stations 2. Voltage Class of GSS 400 kV 220 kV 132 kV Required Area 20.3 While preparing proposals for acquisition of private land and allotment of Government land. the area of land for respective Grid Sub Stations shall be taken into consideration as mentioned in para 2.

1 Last Updated : 31-1-2008 . This Bus bar arrangement was generally used in earlier 220 kV sub stations.3 1.1 1.3. 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. 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.2 1. the entire substation is lost. d) Double Main and Auxiliary bus bar e) One and a half breaker scheme. This scheme suffers from the disadvantage that when any circuit breaker is taken out for maintenance. 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. c) Double bus bar.1. DOUBLE BUS BAR ARRANGEMENT: In this scheme..4 1.1 1.4. this scheme also suffers from the disadvantages that in the event of a fault on the main bus bar or the associated isolator. it employs ‘n + 1’ circuit breakers.0 BUS BAR SCHEMES: The commonly used bus bar schemes at Sub Stations are: a) Single bus bar. a double bus bar arrangement is provided. i.CHAPTER – 2 LAYOUT DESIGN 1.3.2 1. Typical Main and Auxiliary Bus Bar arrangement is shown in Annexure -2. Typical Single Bus Bar arrangement is shown in Annexure – 1. The feeder is transferred to the 1. 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.3.e.2 1.2. bus coupler breaker and Auxiliary bus isolators. 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). Another disadvantage of this switching scheme is that in case of maintenance of circuit breaker.2. the associated feeder has also to be shutdown. SINGLE BUS BAR ARRANGEMENT: This is the simplest switching scheme in which each circuit is provided with one circuit breaker. for ‘n’ number of circuits.3 1. the associated feeder has to be shutdown. Bus coupler breaker is also provided so that the circuits can be switched on from one bus to the other on load. Typical Double Bus Bar arrangement is shown in Annexure – 3.3 1. Each circuit can be connected to either one of these bus bars through respective bus bar isolator.1 1.1 1.2. As in the case of single bus arrangement. b) Main and Auxiliary bus bar. DOUBLE MAIN AND AUXILIARY BUS BAR ARRANGEMENT: The limitation of double bus bar scheme can be overcome by using additional Auxiliary bus.2 1.1. This bus arrangement has been extensively used in 132 kV Sub Stations.

4.5.0 2.3 1. Typical One and a Half Breaker arrangement is shown in Annexure – 5. 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.1 3. both the bus bars are in service.3 2. 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.5 1. 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.0 3.4. 1. protective relaying is somewhat more involved as the central (tie) breaker has to be responsive to troubles on either feeder in the correct sequence.8 Construction Manual for Sub Stations Auxiliary bus during maintenance of its controlling circuit breaker without affecting the other circuits. BILL OF MATERIAL: Lists of material showing the particulars of the material generally required for construction of 132 kV. ELECTRICAL LAYOUT DRAWING: Typical electrical layout drawings and sectional drawings of 400 kV.5.2 1. The lists of material are only typical and cover the general requirement. therefore. any circuit breaker can be taken out for maintenance without causing interruption. Normally. 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. Load transfer is achieved through the breakers and.2 Last Updated : 31-1-2008 . 220 kV and 132 kV sub stations with different bus bar arrangements generally adopted in RVPN are shown in Annexure – 6 to Annexure – 14. ONE AND A HALF BREAKER ARRANGEMENT: In this scheme. Typical Double Main and Auxiliary Bus Bar arrangement is shown in Annexure – 4. However. the operation is simple. 1. Similarly. This scheme has been used in the 400 kV substations. Besides. three circuit breakers are used for controlling two circuits which are connected between two bus bars.1 3.1 1.2 This Bus bar arrangement is generally used nowadays in 220 kV sub stations.5.

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 .

132 kV Tandem Isolator 5. 132 kV Current Transformer for transformer (125 – 250 – 500 / 1A. 33 kV Horn Gap Fuse Set 23. 33 kV CT type B. etc. BO – 1 type for 132 kV Isolators 17. Y – type Column (with stub) 13. 132 / 33 kV Power Transformer 2. Y – type Column (without stub) 14. BT – 6 type Column 4. 132 kV Marshalling Kiosk 13. PIS type for 132 kV PIs 20. GD type (10. 132 kV Circuit Breaker with structure (110 V DC) 6. 110/√3) 9. 3C) 8. 110/√3) 19. Q – type Column (without stub) 9. X – type Column 12.4 Meters for 33 kV) 16. No. R – type Column (with stub) 10. Structures / Beams with nuts. 132 kV Post Insulators 12. GF – type Beam (5. bays) Last Updated : 31-1-2008 . BT – 1 type Column 2. 132 kV Current Transformer for feeder (250 – 500 / 1A. X – 15 type for 33 kV Isolators 21. Z – type Column (with stub) 15. 250 KVA Station Transformer 22. 132 kV Lightning Arrester 10. BB – 1 type Beam 6. P – type Column 7. bolts. washers. 132 kV Isolator without Earth Blade 3. 33 / 0. Particulars A.Layout Design 23 Annexure – 15 LIST OF MATERIAL (TYPICAL) FOR CONSTRUCTION OF 132 kV GRID SUB-STATION S. 132 kV Wave Trap 11. 3C) 7. AO – 5 type for LA’s / CT’s / Bus CVT’s 19. 132 kV Isolator with Earth Blade 4. 33 kV Marshalling Kiosk (one for 2 nos. 33 kV Current Transformer for feeder (125 – 250 – 500 / 1A. 33 kV Current Transformer for transformer (250 – 500 / 1A. BO – 1 (T) type for 132 kV Tandem Isolators 18. 1. 2C) 18. Outdoor Equipment 1. 33 kV Isolator without Earth Blade 14. 5C) 17. 22 kV Post Insulators 21. 110/√3. 33 kV Isolator with Earth Blade 15. BT – 7 type Column 5. 132 kV Capacitor Voltage Transformer (110/√3. 33 kV Potential Transformer (110/√3. BT – 4 type Column 3. 33 kV Lightning Arrester 20.0 Meters) Beam 11. complete. Q – type Column (with stub) 8. 33 kV Circuit Breaker with structure (110 V DC) 16.415 kV.

Single Tension Hardware for Single Zebra (Bolted type) 2. ACSR Zebra Conductor 8. 45 KN 7. GSS Earth wire 19. 200 AH Battery Charger 8. Clamps for 7 / 3. P. P. G. 2. type. 1A) 3. T. 120 KN 6. LT Power Cable (Aluminium) 1. mm. 3. S. P. Others / Miscellaneous 1. M. 1A) 4. mm. Particulars C. Copper Control Cables 1. Fire Fighting Equipment 1. P. 4 core × 2. C. 5. G. I . 6. 1A) 6. 132 kV Feeder Control & Relay Panel (110 V.5 sq. No.Clamps for Panther 17. Channel 100 × 50 × 6 mm. Clamps for Panther to Panther 15.24 Construction Manual for Sub Stations S. 132 kV Bus Coupler Control & Relay Panel (110V. 2.5 sq. 132 kV side of Transformer Control & Relay Panel (110 V. 110 Volts D. M. 33 kV side Control & Relay Panel for Transformer & Bus Coupler (110V. mm. 1A) 2.15 mm. Control Room Equipment 1.5 sq. Flat 50 × 10 mm. CO2 type. S. 110 Volts.5 sq. 200 AH Battery Set 7. L. 4 core × 4 sq.15 mm. 3 core × 2. G. D. F. T – Clamps for Panther to Panther 12. 3. feeders (110V. mm. Tension Hardware for 7 / 3. mm. Flat 50 × 6 mm. Last Updated : 31-1-2008 .15 mm GSS Earth wire 18. P. Single Tension Hardware for Panther (Bolted type) 3. ACSR Panther Conductor 9. Earth wire E. Single Suspension Hardware for Panther 5. M. Round 25 mm. dia. 7 / 3. 2. 11 KV Disc Insulators. Earthing Material 1. 33 kV Feeder Control & Relay Panel for two nos. P. Clamps for Zebra to Zebra 13. 12 / 10 core × 2. T – Clamps for Zebra to Panther 11. S. Distribution Board 9. 18 / 16 core × 2. T – Clamps for Zebra to Zebra 10. C. 6 core × 2.5 sq. H. 11 KV Disc Insulators. 110 Volts. G. I . Clamps for Zebra to Panther 14. 4. S. mm.Clamps for Zebra 16. Distribution Board (110 V DC) D. 1A) 5. Copper Earth Bond I. 2. mm. M. P. G. Bus Bar Material 1. Single Suspension Hardware for Single Zebra 4. 3½ core × 300 sq.

AT – 3 type Column 3. AO – 3 type for 220 kV CT’s 15. 220 kV Post Insulators 12.415 kV. 220 kV Current Transformer (400 – 800 / 1A. 4C) 18. 110/√3) 9. 132 kV Marshalling Kiosk 23. No. 110/√3) 19. 5C) 8. 132 kV Circuit Breaker with structure (220 V DC) 17. BT – 6 type Column 10. AO – 4 type for 220 kV CVT’s 16. 220 kV Circuit Breaker with structure (220 V DC) 7. Structures / Beams with nuts. CVT’s / PT’s.Layout Design 25 Annexure – 16 LIST OF MATERIAL (TYPICAL) FOR CONSTRUCTION OF 220 kV GRID SUB-STATION S. BT – 4 type Column 9. 220 / 132 kV Power Transformer 2. 132 kV Capacitor Voltage Transformer (110/√3. BO – 1 (T) type for 132 kV Tandem Isolators 19. 132 kV Isolator without Earth Blade 14. 132 kV Post Insulators 22. etc. 132 kV Isolator with Earth Blade 15. 220 kV Capacitor Voltage Transformer (110/√3. 220 kV Lightning Arrester 10. washers. AT – 4 type Column 4. 220 kV Isolator without Earth Blade 3. bolts. 1. complete. PIS type for 220 kV & 132 kV PI’s B. 132 kV Wave Trap 21. Outdoor Equipment 1. AO – 1 (T) type for 220 kV Tandem Isolators 14. AT – 1 type Column 2. Particulars A. 220 kV Wave Trap 11. 220 kV Isolator with Earth Blade 4. 220 kV Isolator with Double Earth Blade 5. 220 kV Marshalling Kiosk 13. AT – 6 type Column 5. AO – 1 type for 220 kV Isolators 13. AB – 1 type Beam 7. AT – 8 type Column 6. BT – 1 type Column 8. AO – 5 type for 220 kV LA’s & for 132 kV CT’s. 132 kV Tandem Isolator 16. 132 kV Current Transformer (250 – 500 / 1A. BB – 1 type Beam 12. LA’s 17. 220 kV Tandem Isolator 6. BT – 7 type Column 11. 250 KVA Station Transformer Last Updated : 31-1-2008 . 132 kV Lightning Arrester 20. 33 / 0. BO – 1 type for 132 kV Isolators 18.

7. 120 KN 8. L. S. Particulars C. ACSR Panther Conductor 11. F. 5. mm. 6 core × 6 sq. mm. Control Room Equipment 1. 220 Volts. mm.5 sq. 6. LT Power Cable (Aluminium) 1. 1A) 7. Clamps for 7 / 4. M.00 mm.00 mm. S. P. P. T – Clamps for Zebra to Zebra (Z – Z) 14. I .5 sq. 400 AH Battery Set 8. G. 11 kV Disc Insulators. GSS Earth wire 23. 3½ core × 300 sq. 7 / 4. 2. 2. G. T. mm. Earth wire E. P. 132 kV Feeder Control & Relay Panel (220 V DC. mm. Round 28 mm. 1A) 3. Distribution Board 10. P. T – Clamps for Zebra to Panther (Z – P) 15. 6 core × 2. M. G. Tension Hardware for 7 / 4.00 mm GSS Earth wire 22. Single Tension Hardware for Panther (Bolted type) 4.Clamps for Panther 21.26 Construction Manual for Sub Stations S. Single Suspension Hardware for Double Zebra 5. 132 kV side of Transformer Control & Relay Panel (220 V DC. C. 3. 220 kV Feeder Control & Relay Panel (220 V DC. 18 / 16 core × 2. dia. P. Copper Control Cables 1.Clamps for Zebra 20. 132 kV Bus Coupler Control & Relay Panel (220 V DC. M. Clamps for Zebra to Zebra (Z – Z) 17. 220 Volts D. I . G. Bus Bar Material 1.5 sq. 4 core × 2. 3. Flat 50 × 12 mm. 220 Volts. Last Updated : 31-1-2008 . Single Suspension Hardware for Single Zebra 6. 1A) 2.5 sq. S. mm. 3 core × 2. 220 kV side of Transformer Control & Relay Panel (220 V DC. Earthing Material 1. 4. Clamps for Panther to Panther (P – P) 19. G.5 sq. ACSR Zebra Conductor 10. 1A) 4. 220 kV Bus Coupler Control & Relay Panel (220 V DC. 1A) 5. T – Clamps for Panther to Panther (P – P) 16. 70 KN 9. 1A) 6. mm. 11 kV Disc Insulators. Spacer T – Clamps for Double Zebra to Panther (ZZ – P) 13. P. 4 core × 4 sq. No. Single Tension Hardware for Single Zebra (Bolted type) 3. Flat 50 × 6 mm. Single Suspension Hardware for Panther 7. Clamps for Zebra to Panther (Z – P) 18. 400 AH Battery Charger 9. Spacer T – Clamps for Double Zebra to Zebra (ZZ – Z) 12. 12 / 10 core × 2. Distribution Board (220 V DC) D. mm. Single Tension Hardware for Double Zebra (Bolted type) 2.

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

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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.5 sq. Earthing Material 1. Fire Fighting Equipment 1. 28. M. Clamps for 7 / 4. 6 core × 2. 5. C. Earth wire 33 kV Side: Transformer clamp for 52 kV Bushing for 72.5 sq. 27. Flat 100 × 12 mm. Flat 75 × 12 mm 4. 12 / 10 core × 2. 6. type 2. 3 core × 2. c) 1. 22 kV PI Clamp for 72. 5. 4.Layout Design 31 Particulars ACSR Conductor ‘ZEBRA’ Tension Hardware for 7 / 4. LT Power Cable (Aluminium) 1.03 mm dia. S.03 mm dia. 6 core × 6 sq.03 mm dia. mm. I. S.00 mm. Flat 50 × 12 mm. Flat 50 × 6 mm. Last Updated : 31-1-2008 . 2. Copper Earth Bond I. mm. Aluminium pipe (Expansion type) 4. mm. Aluminium pipe (Expansion type) 3. 22 kV PI Clamp for 72. Channel 100 × 50 × 6 mm.00 mm GSS Earth wire 7 / 4. GSS Earth wire P. mm. 25. Round 40 mm.5 sq. 3. 3½ core × 95 sq. CO2 type S. dia. G.00 mm. 7. M.5 sq. Others / Miscellaneous 1. Aluminium pipe (Expansion type) 2. mm. S. F. M. P. 2. mm. 18 / 16 core × 2. S. 4 core × 2. D. S. Copper Control Cables (FRLS) 1. 2. 26. 3. 4 core × 4 sq. 3½ core × 300 sq. G. No. H.5 sq. 52 kV PT Clamp for 72.03 mm dia. Aluminium pipe (Rigid type) E. mm. M. G. mm. M. 2.

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

CHAPTER – 3 SAFETY CLEARANCES 1. These include the minimum clearances from live parts to earth. temperature and moisture.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. A correction factor of 1. 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. Last Updated : 31-1-2008 . 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. For safety of personnel moving in the switchyard with tools & plant.0 1. etc.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.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. effect of short circuits. wind effects and safety of personnel. 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. between live parts of adjacent phases and sectional clearance between live parts of adjacent circuits / bays.

3. 6. 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.3 As per Rule 64 (2) of the Indian Electricity Rules. 2. “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. iii) Last Updated : 31-1-2008 . 1956. 1. the following safety working clearances shall be maintained for the bare conductors and live parts of any apparatus in any Sub Stations. 5.25 percent per 100 Meters is to be applied for increasing the clearance for altitudes more than 1000 Meters and up to 3000 Meters. A correction factor of 1. ii) The above safety working clearances are based on an insulator height of 2440 mm. which is the height of lowest point on the insulator (where it meets the earthed metals) from the ground.34 Construction Manual for Sub Stations 1. excluding over head lines of HV and EHV installations: Table for Safety Working Clearance Sl. No. 4.

1. It is. 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. 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.CHAPTER .4 2. should be within safe limits.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. b) c) 1.1 2.0 (ONE) Ohm. The Step Potential. MEASUREMENT OF EARTH RESISTIVITY: Weather Conditions: The resistivity of earth varies over a wide range depending on its moisture content. An appropriate range on the instrument. none of these parts is at a potential higher than that of the earthing mat. advisable to conduct earth resistivity tests during the dry season in order to get conservative results.4 EARTH MAT DESIGN 1. 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). Touch Potential. The earth resistance Megger is placed on a steady and approximately level base.2 To meet these requirements. The depth of the electrodes in the ground shall be of the order of 30 to 50 cm. therefore. 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. Test Procedure: Four electrodes are driven in to the earth at equal intervals s along a straight line in the chosen direction.0 1. is then selected to obtain clear readings. All the structures & equipments in the Sub Station are connected to the earthing mat so as to ensure that under fault conditions. The neutral points of different voltage levels of transformers & reactors are separately earthed at two different points. Each of these earthed points should be interconnected with the station earthing mat.2 Last Updated : 31-1-2008 . avoiding the two ends of the scale as far as possible. should also be within safe limits. the link between terminals P1 and C1 is opened and the four electrodes are connected to the instrument terminals as shown in the figure.3 1.0 2.

increasing from 1 metre to 50 metres in the steps of 1. 10. 2. It is desirable to get information about the horizontal and vertical variations in earth resistivity over the site under consideration. 25 and 50 metres. and R = Megger reading in ohms.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. shall be submitted to the Superintending Engineer (400 KV Design) for designing the earth mat.3. along with a sketch showing the directions in which earth resistivity readings have been taken. These readings. 15. 2. 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. A diagram showing the typical layout for earth resistivity measurement in 6 directions is enclosed. s = distance between two successive electrodes in metres.2 Last Updated : 31-1-2008 . 5.3 2.3.1 Testing Soil Uniformity.

15 M 6.Earth Mat Design 37 2. 15 M 6. 25 M 7. 50 M Similarly for Direction 3 to Direction 6. Last Updated : 31-1-2008 . 1M 2. 2M 3. 5M 4. 25 M 7. 10 M 5.3. 10 M 5. Electrode Spacing Megger Reading in Ohms Earth Resistivity in Ohm – metres Remarks Direction 1 1. Sl. 5M 4. 2M 3. 1M 2.3 An example of the format in which the earth resistivity readings are to be recorded is given below. No. 50 M Direction 2 1.

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

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

Last Updated : 31-1-2008 .

templates.0 6. all surplus material including bolts and nuts. may be utilized for erection. should of sufficient strength to take the load of the equipment to be erected. Transformer bushings and other fragile equipment shall preferably be handled carefully with cranes having suitable boom length and handling capacity. Mulmul cloth shall be used for cleaning the inside and outside of hollow insulators. testing and commissioning manual / instructions procedures of the manufacturer.CHAPTER . All support insulators. After completion of the erection work. Whenever the work is required to be got done at the existing GSS where the adjacent portions may be charged.0 12. All unusable cut lengths of material such as conductor. The Work – In – Charge shall ensure that the work is completed within the requisitioned time. Sling ropes.1 GENERAL INSTRUCTIONS 1.0 11. etc. etc. 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. Erection of equipment shall be carried out as per and in the manner prescribed in the erection. The slings should be of sufficient length to avoid any damage to insulator or other fragile equipments due to excessive swing. Wherever it is necessary to avail shutdowns of energized circuits for carrying out any work.charge of the GSS stating the date. The services of the manufacturer’s Engineer. 2. testing and commissioning of sub station equipment. the Work – In . effective earthing must be ensured for safety against induced voltages so that work can be carried out without any danger / hazard to the workmen. has been done. All the material and equipment shall be checked as per Bill of Material (BOM). etc. shall be returned to the store. time and duration of the shutdown and the section / portion which is to be kept out of circuit during the shutdown.0 8.0 5. circuit breaker poles.0 13.0 Last Updated : 31-1-2008 . wherever necessary. shall not be treated as wastage and shall also be deposited in the store.0 3.0 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.0 9. They should be checked for breakages of strands before being used for the erection of equipments.0 4.0 7.Charge shall submit a requisition to the Engineer In . etc.0 10. earth wire. scratching by sling ropes. aluminium pipes. on which work is to be carried out.

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

CHAPTER . ropes. 2.5 10.0 / 14.0 1. EHB B. No. 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. 10.3 (Width) A.5 25. 3.0 / 11. 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. tackles.0 / 14.0 / 11. derrick.0 / 14.2 GENERAL INSTRUCTIONS: The structure material shall be stacked member / item wise. etc.5 and 9.6 (Width) 4.5 16.5 16. 9.2 (Width) 2.1 1.5 8.0 / 9. jacks. 2.5 / 7. 400 kV Structures: 1. spanners. AT8 6. 3.2 STRUCTURES 1.5 12.5 20. 5.0 / 20. AT6 5.5 12.5 12. 1. EHT1 2.5 15. Name of Structure Type of Structure Height of Column / Height of Conductor (Meters) 27.0 (Width) Last Updated : 31-1-2008 . winches.5 15. 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. 1.0 / 11. T & P such as levelling instruments. 6.0 2.5 7.5 3. AB C.0 / 7. 7. 220 kV Structures: AT1 AT3 AT4 Column with Peak Beam 4.5 and 7.1 TYPE OF STRUCTURES: The types of structures generally used at sub stations are given below: Sl. 2.0 / 9. Templates of structures.0 / 7.0 10. 8.

The length of the foundation bolts above the template shall be sufficient so that all parts of the base plate assembly of the structure. X – 15 9. AO3 4. the assembled lower part of the structure is placed on the foundation. the template.44 Construction Manual for Sub Stations Sl. 1. 4. shall be placed on the foundation.4 GF – 4. 2.4 (Width) 4. BO1 7. 33 kV & 11 kV PI ------------ 3.0 5. AO1 (T) 3. CVT / PT.2 3. While levelling and centering the structure / template. No.6 (Width) Equipment Structures: 1. AO1 2. LA 132 kV Isolator 132 kV Tandem Isolator 33 kV & 11kV Isolators 33 kV & 11kV Tandem Isolators 33 kV & 11kV CT. Name of Structure Type of Structure Height of Column / Height of Conductor (Meters) 33 kV and 11 kV Structures: X Y Z GF – 5.5 5. PI Structure 220 kV Isolators 220 kV Tandem Isolators 220 kV CT 220 kV CVT 220 kV LA & 132 kV CT. CT Structure 11. D. nuts and lock nuts can be tightened fully and 2 – 3 threads are left above the lock nut. The template is levelled & centered with reference to its location on the foundation. X – 15 (T) 10. LEVELLING AND GROUTING: In case of structures with foundation bolts. the following points should be checked: 3. AO5 6. E. AO4 5.0 3. 5.5 3. This is levelled & centered with reference to its location on the foundation.1 SETTING OF STUB / FOUNDATION BOLTS.5 / 5.3 3. In case of structures with stubs.6 Peak Column Extension Beam for 33 kV Beam for 11 kV 1. 3. PT 220 kV. The stubs / lowest member shall thereafter be grouted ensuring that there is no displacement during the placing of the concrete and use of vibrator. The foundation bolts shall thereafter be grouted ensuring that there is no displacement during the placing of the concrete and use of vibrator. the template with stubs shall be placed on the foundation. BO1 (T) 8. along with the foundation bolts tightened on it with nuts on both sides. 132kV.4 Last Updated : 31-1-2008 . In case of structures in which the lowest member is used as a stub. washers.

Centre to centre distance between structures. On sloping or uneven ground.4 4.3. The complete structure is assembled in a horizontal position near its location.1 4.4.0 4. to eliminate / minimize stress on the structure members.2.1 4. which are as below: i) Ground assembly method. the first face of the second section is erected.3. After the two opposite faces have been erected. After the structure top is erected and all side bracings have been bolted up. suitable packing is provided in the lower level area before or during assembly. Alternatively. as required. A mobile crane is used for erecting the structures.1 4. The last lift raises the top of the structure.1 ERECTION OF STRUCTURES: Method of Erection: There are mainly three methods of erection of structures. The level of the structure / template with reference to level of other similar structures. for example.2 4. 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.4 4.2. In case where the major sections of the structure have been assembled.3 4. Section Method: This method is used for large and heavy structures when crane facility is available. the structure is picked up from the ground with the help of a crane and set on its foundation. the two faces / sides of the major sections of the structure are assembled on the ground and the same are erected as units.2 4. by a common beam. One side is held in place with props or rope guys while the other side is being erected. iii) Built up method or Piecemeal method.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. The structure members are kept on ground serially according to erection sequence so that they can be sent up conveniently.3 4.Structures 45 a) b) c) d) Level of structure / template with reference to the finished foundation level or the ground level. This method consists of assembling the structure on the ground and erecting it as a complete unit. This method consists of erecting the structure member by member.4. The two opposite sides are then connected together with cross members. ii) Section method.3. the bracings on the other two sides are bolted up. particularly structures which are to be connected together. Built up method or Piecemeal method: This method is used for large and heavy structures when crane facility is not available.2.4 4. 4.2. 4.2 Last Updated : 31-1-2008 .2 4. Distance of centre line of the structure from the center line of other structures or from a reference point. After the assembly is complete.5 4.3.3 4. all the guys are thrown off. The two faces / sides of the complete structure are assembled on the ground and then erected.

The leg members and bracings of this section are then hoisted and assembled.4 4.4. 4. 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.0 Last Updated : 31-1-2008 . The bracings of the upper and lower faces of the beam are then raised up and fitted. ERECTION OF BEAMS: The two faces of the beam are assembled on the ground.3 The erection progresses from the bottom upwards.1 5. The four main corner leg members of the first section of the structure are first erected.4. For assembling the second section of the structure. a derrick is placed on one of the corner legs.4.2 5.0 8.6 5.0 5. If these have been assembled on the ground. All bolted connections shall be well tightened using spring washers & then punched at three points on the circumference of the bolt.46 Construction Manual for Sub Stations 4. This derrick is used for raising parts of second section.0 7. 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. then they are lifted up as a unit. Single or multi – way pulleys with polypropylene / steel ropes are used as per load requirement. The cross bracings of the first section are raised one by one and bolted to the already erected corner leg angles. The derrick is thus moved up as the structure grows. The columns shall be truly vertical and the beams truly horizontal after erection.5 4.3 6.4. 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. 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 ends of the beam are connected to the column as per fixing arrangement provided on the columns. This process is continued till the complete structure is erected.

33 kV equipment interconnection. 15. 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. 400 kV equipment interconnection 3.0 1.2 mm dia. 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.CHAPTER .2 mm dia. 4. 1.0 2. 132 kV overhead bus & droppers in all bays. 33 kV Auxiliary Bus 14. 220 kV Auxiliary Bus 6. 11 kV equipment interconnection. 132 kV equipment interconnection 11. overhead bus and droppers: (i) Bus coupler & transformer bay (ii) Feeder bay. 11 kV Main Bus 16. BUS BAR MATERIAL: The bus bar material generally used in 400 kV.3 2.3 BUS BAR & EARTH WIRE 1. 11 kV Auxiliary Bus 17. 220 kV equipment interconnection 7.2 1. 8. Description No. 220 kV Main Bus 5. 220 kV overhead bus & droppers in all bays. 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. Aluminium pipe 114. Cut lengths of conductor and earth wire left after stringing of bus bars and earth wire can be used for jumpering work.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 . overhead bus and droppers: (i) Transformer bay (ii) Bus coupler (iii) Feeder bay. 132 kV Main Bus 9. 400 kV Main Bus 2. 12. 132 kV Auxiliary Bus 10.1 GENERAL INSTRUCTIONS: Care shall be taken during sagging operations so that no damage or deformation is caused to the structures. 33 kV Main Bus 13. 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. 400 kV overhead bus & droppers in all bays. Bus Bar and Jumper Material 114. 220 kV & 132 kV substations is given below: Sl.

6. 4. 3. 3. cm. 2.48 Construction Manual for Sub Stations 3. Nos. When the conductor is to be taken from drums. 1. 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. the complete hardware assembly with the conductor shall be hoisted up and fixed on the beam at this end. 20000 b) Total Glaze Defect = 1.6 3. For stringing of bus bars. 5. No. The conductor along with tension hardware set shall then be again pulled up and connected to the beam.5 + 3. 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 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.4 Suspension String Tension String E&M E&M Nos.7 Last Updated : 31-1-2008 . 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. D = Diameter of the disc in cm. F = Creepage distance in cm. Thereafter. etc. 3. the conductor shall be fixed and tightened in the clamp of the tension hardware on one side of the bus. Disc insulators shall be cleaned and examined for any cracks / chipping. the conductor drum shall be placed on a turn table or jacked up on a suitable size of steel shaft.0 + D× F Sq. small lengths can be unwound from the drum. Sagging arrangement shall be made on the other end of the bus and the conductor shall be tensioned.2 D× F Sq. For longer lengths. Sl. a) Single Glaze Defect = 0.3 The disc insulators shall be assembled on the ground to form the suspension and tension strings as given below. the mouth of the W – clips / R – clips shall be widened to prevent any inadvertent removal during service. 3. cm. Disc insulators having any hair cracks or chipping or defective glazing or any other defect shall not be used.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. 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. 2000 where.0 3. The limits of the area of defective glazing are given by the following formulas.

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.4 4. 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. The jumpering between equipment shall be done with single / twin / quadruple conductors as per the terminal connectors provided on the equipment. Spacers are not used at jumper points in case T – Spacers are used for taking jumpers from multi conductor bus bars.1.1.1 4.4. PG – clamps as shown in the diagram above. clamps.e. the suspension hardware set along with disc insulators shall first be hoisted and fitted on the beam. 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.9 4. 4. the bus bar conductor(s) shall be again connected with the jumper conductor(s) using properly curved & shaped Y – conductor(s) and 2 nos.3 4. The spacers shall also be provided at points where jumpers are taken from the bus bar using T – clamps and / or P. the spacers shall also be fitted at a suitable spacing on the jumpers in order to maintain their shape.1 4. The spacers shall be fitted on the twin and quadruple conductor bus bars at the spacing shown in the drawing.8 Equalizing of tension in the different sub – conductors of the same phase and in the different phases shall be done.2 Last Updated : 31-1-2008 . if required.4. 3. G.2 4.1.. In case of jumpers for twin and quadruple conductors. i. 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.Bus Bar & Earth Wire 49 3. Thereafter. bus bar conductor(s) and the jumper conductor(s). Conductor of approximately the length required for the jumper shall be cut and straightened so that kinks are removed.3 For making Y – type jumpers. A typical diagram of Y – type jumpering is given below.2 4.0 4. JUMPERING OF BUS BARS: For jumpering of different sections of bus bars on the beam.

The earth wire shall be strung from one peak to another peak of the structures as per layout of the GSS. After cutting the conductor to the required length.5.2 5. Generally. The conductor shall be cut to the appropriate length and then connected to the bus bar conductor on the other side.5 4.3 5. In case the jumper is to be connected to equipment / pipe bus near or under a beam.1 4.1 4.6. an angle of shield of 60° for zones covered by two or more wires and 45° for single wire is considered adequate.0 5. 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.5. The measurement of length of the conductor up to the equipment / pipe bus shall be made.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.6. the suspension hardware along with disc insulators is first fitted on the beam. 4. The shield / earth wire shall be handled with care to prevent scratches on it or damage to the strands of the wire. The tension hardware shall be assembled as per the relevant drawings. For longer lengths. 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.5 4. Vertically supported insulators of equipments and Post Insulators should be checked for verticality again after jumpering on both sides. STRINGING OF SHIELD / EARTH WIRE: Sub Station is shielded against direct lightning strokes by overhead shield wire / earth wire. JUMPERING BETWEEN EQUIPMENTS: The distance between terminal connector of one equipment and terminal connector of other equipment is first measured.1 5. The conductor shall be passed through the clamp of the suspension hardware. The clamp of the suspension hardware shall then be tightened after ensuring proportional lengths of the conductor on both the sides of the beam.2 4.2 4. it shall be connected to the equipment / pipe bus. the wire drum shall be placed on a turn table or jacked up on a suitable size of steel shaft.4 Last Updated : 31-1-2008 .3 4. if required. 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. When the shield / earth wire is to be taken from drums.6.6 4. The end of the conductor shall be taken up to the terminal connector of the equipment / connector fitted on the pipe bus.4 4. 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.5.50 Construction Manual for Sub Stations 4. 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.5.3 This shall then be passed through the clamps on the suspension hardware so that the proper curve is obtained. small lengths can be unwound from the drum.3 5. The clamps of the suspension hardware shall be tightened thereafter.5. and corrected. The appropriate length of the conductor shall be cut and then straightened so that curves and kinks are removed.

2 Last Updated : 31-1-2008 . for the purpose of connecting the shield / earth wire to the earth mesh of the sub station.5 The shield / earth wire shall be fitted and tightened in the clamp of the tension hardware on one side. Thereafter. 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. if required. which is used as a down conductor from the peak. if required.6 5.7 6. 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.1 6. 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.Bus Bar & Earth Wire 51 5. Adjustment of tension in the earth wire may be done. 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. 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. so that these lengths when joined together form a smooth and proper curve. The shield / earth wire along with tension hardware set shall then be pulled up again and connected to the peak of the structure. These shall be connected together using a PG –Clamp. Sagging arrangement shall be made on the other end and the shield / earth wire shall be tensioned.0 6.

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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Construction Manual for Sub Stations

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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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Aluminium Pipe Bus Bar and Joints

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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 .

The Bushing CT’s fitted in the turrets should be got tested by the protection wing before erection of turrets. it should be maintained by filling in gas from the cylinder on the transformer.8 Last Updated : 31-1-2008 . radiators. Installation and Maintenance of Transformers: Installation.6 1. 1. The gas pressure in transformers received gas filled should be checked periodically. headers.7 1.15 kg / cm2 at 30° C) should always be maintained.L. Transformer Manual (Technical Report No.5 1.4 All the accessories should generally be stored in a closed shed / room. 1. Transformer oil drums should not be stored in low lying areas.0 1. The weather conditions during transformer erection should be dry.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. 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. Buchholz relays. conservator.. accessories such as condenser bushings. In case of reduction in pressure.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. 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. The transformer tank should not be opened when it is raining. pipe work and A – frame can be stored under covered sheds. Oil surge relays. However. 1. Check the open and closed conditions of contacts provided in equipment such as M.G.3 1. A positive pressure (generally 0. etc. Manufacturer’s Erection Drawings. before they are installed. 1) issued by the Central Board of Irrigation & Power.CHAPTER – 5 POWER TRANSFORMERS 1.O. oil flow indicators. IS: 10028 (Part II) – 1981: Indian Standard Code of Practice for Selection.

1 The oil temperature thermostat in the filter machine should be set at 60°C. This oil is then filtered in the tank(s).2 Last Updated : 31-1-2008 .5 2.3.1 2.1.3.4 2.2.2 2.1 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.2.4. and for erection if required.4 2.3 2.2 2. 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. The oil is drained from the tank for internal inspection.2.2.00 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. The extent of vacuum and the time duration of its application shall be as per Manufacturer's recommendations.2 2.1.9 The top oil temperature should invariably be noted during measurement of IR values of transformer.1 2.3 2. The vacuum pipe is generally connected to the pipeline between transformer tank and conservator. 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) 1.10 2. topping up & OLTC) is first filled into oil storage tank(s) through filter machine. 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. the oil is refilled after the day’s erection activities are completed. Apply vacuum to the transformer.4. 2.2. Where connections are required to be made inside the tank and when the erection work is to be continued on the next day. 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. 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. then vacuum of 1. 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. Erection of the part of the pipeline between the tank and the conservator up to the Buchholz relay.58 Construction Manual for Sub Stations 1.2 2.1 2. In case this is not specified by the Manufacturer. Initial oil filling in Transformers received gas filled: Oil Preparation: The oil supplied in oil drums (for first filling. The oil level can be seen in the transparent plastic pipe provided.0 2. Connect a breather to any valve above the tank oil level through a suitable pipe.

Assembly and fitting of upper and lower cooler pipe line from transformer tank to respective headers including fixing of Valves. Erection of HV. Transformers with separately mounted cooler banks: Large size EHV Transformer (generally 245 kV class and above) are provided with separately mounted cooler banks. as per General Arrangement (GA) drawing.4 4. Assembly and fitting of equalizing pipeline between tank cover.0 The oil received in drums (for topping up & OLTC) for transformers received oil filled is filled into a storage tank through filter machine. The arrow marks on the oil pumps and oil flow indicators should point towards the transformer tank. and connecting it to the equalizing pipeline and the main conservator. as provided. 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.2 are attained. if provided. fitting of valves. Where two Buchholz relays are provided. when supplied separately..1 5.3 6. Fitting of Pressure Relief Devices along with pipes. Erection of radiators on headers / tank.1 6. Pumps. 3. LV and TV turrets. Erection of HV.2 6. if provided. Erection of Radiators on the headers. expansion joints.2 4. Ensure that diaphragms are fitted on both ends of the vent pipe. 4. if not of blue colour). levelling and centering of cooler bank supports (A – frame). The arrow marks on the Buchholz relays should point towards the conservator.Power Transformers 59 Additional precautions prescribed by the Manufacturer for dry air and human safety during such erection activities should be followed.6 5.5 4. Transformers with tank mounted cooler bank / radiators: Erection of headers. oil flow indicators.7 6. Erection of Accessories: Erection of main conservator & On Load Tap Changer (OLTC) conservator along with their supports. etc. expansion joints as provided and Buchholz relays.0 4. Non Return Valves.0 6. turrets. if provided. This oil is filtered in the tank until the values given at para 2. Placing on foundation.4 6.1 4.8 Last Updated : 31-1-2008 . etc. LV.1.5 6. Grouting of cooler bank supports (A – frame).2 6.3 4. as required. Erection of lower and upper headers on the A – frame. Assembly and fitting of Buchholz pipeline. TV & neutral bushing(s) and making their connections inside the tank. inspection covers.0 5. the relay near the tank is designated as Buchholz Relay – I and the relay near the conservator as Buchholz Relay – II. Erection of Explosion Vent.6 6.

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

The process at (d) is mostly adopted and is described at para 8. Last Updated : 31-1-2008 . the manufacturer is to be contacted.10. vacuum pulling and Nitrogen filling.10 8. the insulation resistance changes by a ratio generally in the range of 2:1 to 1.1 Drying by Hot oil circulation and vacuum pulling: Carry out hot oil circulation on the transformer. the hot oil circulation is continued for 2 – 3 volumes of the transformer oil. The IR values and the temperature are noted. Insulation resistance varies inversely with the temperature. Heating. then carry out further drying out by adopting any of the following processes. For a 10°C change of temperature.Power Transformers 61 8. Previous Test Results. The processes at (a). 8. as convenient. (b) and (c) are described in the CBIP Manual on Transformers (Publication no. If the specified IR values are achieved. After maximum top oil temperature is attained.4:1. Hot oil circulation and vacuum pulling.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. However.8 Compare the insulation resistance values with the following reference values: i) ii) New transformers: Old transformers: Factory Test Results. 295) and in the IS : 10028 (Part – II) – 1981. a) b) c) d) Hot air circulation. in case of transformers within guarantee period.9 If the specified IR values are not attained. Hot oil circulation and short circuit heating.9 below. 8. the transformer can be charged.

10. as given earlier. The precautions.5) are to be followed.6 8.2 9.3 8. otherwise it is continued till two consecutive readings are same. The IR values and the temperature are noted.2. If the previous IR values are achieved. which is provided with a pressure gauge and a filling pipe in which a non return valve is fitted.10.1.62 Construction Manual for Sub Stations 8.4 Last Updated : 31-1-2008 . Start hot oil circulation and continue for 2 – 3 volumes of the transformer oil after maximum top oil temperature is attained. 9. If still there is no change. The IR values as measured above at para 8. Fill the oil again into the transformer. then the drying out process is stopped.3 is carried out. If there is improvement in the IR values. Drain the oil from the transformer through the bottom filter valve till the conservator is empty.10. Any valves in the breather pipe should be kept open. then another cycle of the above process as given at para 8.1 9.1 kg / cm².1) as well as for allowing dry air into the transformer while draining oil (para 2. the transformer can be charged. 8. the drying out process is stopped and the transformer is allowed to cool down to atmospheric temperature. Inject air into the Air Bag / PRONAL through the air filling device to a maximum pressure of 0.3 are compared.10. If there is no change in the IR values as measured above at para 8.1.10.4 8.1 & para 8. These are compared with the reference values.3 Remove the breather.10. After constant IR values are achieved.2 & para 8. The IR values are then measured and the temperature is noted.1 & para 8. then the above process as given at para 8.1.10.10. This can be checked by ensuring that there is no oil in the Buchholz relay(s). Connect the air filling device.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.10.10.11 9.5 8.0 9.2 & para 8.10.10.3.3 is continued till two consecutive readings are same.1 9. to the breather pipe.2 Drain the oil from the tank and apply vacuum immediately and maintain for 12 hours.1. for application of vacuum (para 2.2.

Filling of oil in OLTC and its Dehydration: Fill filtered oil (as per para 2. Close the air release valve such that the flow of oil will be very slow.2.0) in the OLTC diverter switch chamber(s) and the OLTC conservator. Connect the air filling device. Release the air pressure thereafter.3 9. The air in the conservator outside the Air Bag / PRONAL is pushed out through the air release plugs / valves.1 9. they should be fitted but not fully tightened. Refit the breather on the pipeline.2.4 9.1 kg / cm². 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.2. Release the air pressure thereafter. Refit the breather on the pipeline.2 Last Updated : 31-1-2008 . oil along with air bubbles starts coming out of the air release plugs / valves. which is provided with a pressure gauge and a filling pipe in which a non return valve is fitted.9 10. Where air release plugs are provided.2. 9.1. only oil will come out through the air release plugs / valves.2 9.5 Slowly pump the oil through the bottom filter valve.2.0 10. Temporarily stop the oil filling operation when oil along with air bubbles starts coming out of the air release plugs / valves. if provided on the conservator.9 9. The oil is allowed to come out until there are no air bubbles in the oil.5 9.2. The air release plugs / valves are then closed while still maintaining the air pressure. to the breather pipe.1 / para 3. Continue the oil filling. Inject air into the Air Bag / PRONAL through the air filling device to a maximum pressure of 0. 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. This oil is filtered in the OLTC diverter switch chamber(s) until the values given at para 8.1. The prismatic oil level gauge provided on the conservator will indicate full oil level.6 9. Remove the breather.8 9. Carry out dehydration of the oil.1. Oil mixed with air bubbles shall start coming out.2 9.7 9.10 9. Alternate Method / Field Practice: Keep the oil level in the conservator at approximately 1/3rd level.2.1 10.7 9. The prismatic oil level gauge.1.8 9.6 9.Power Transformers 63 9.2.2. Stop the oil filling after ensuring that no air bubbles come out with the oil. When all the air has been expelled. When all the air has been expelled. Any valves in the breather pipe should be kept open.1. Close the air release plugs / valves while still maintaining the air pressure.1.1. will indicate full oil level. Open the air release plugs / valves provided on the top of the conservator.7 are attained.

Assembly of OLTC Drive Mechanism & Operating System: Fix the brackets. P. ensure that the tap position indicated in the OLTC drive mechanism and at the head of OLTC diverter switch(es) are the same. Problems arising out of peculiar situations are to be assessed and solved on case to case basis.3 13. I.0 12. P.0 11. if provided.64 Construction Manual for Sub Stations 11. Protective covers for OLTC operating shaft(s). attention should be paid to the checks and tests given in the following paras. as provided. Condenser type Bushings. Lock the bolts & nuts of the coupling brackets of the operating shaft(s).2 13. f) Air release screws on through oil type Bushings (up to 33 kV). gear boxes and operating shafts between OLTC drive mechanism and OLTC diverter switches. to the fan control cubicle / marshalling box / Temperature meter box.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. Synchronize the operation of all the three OLTC diverter switches so that all the three phases operate almost simultaneously.1 13. Fix the cables on these cable gland plates and connect the wires as per schematic drawing. Fixing of cable trays / brackets on the tank cover and clamping of cables on them. b) Air release plugs provided on the Radiators. When connecting the operating shaft(s).4 14. The checks / tests given hereafter are generally applicable.0 15. g) Air release screws / plugs if provided on the mounting flange of O.0 13. the transformer is to be made ready for commissioning. Prior to putting the transformer into service. Any other accessories.3 13. Specific checks / tests prescribed by the manufacturer are also to be carried out.2 12. e) Pressure relief device (PRD) and Explosion Vent (if provided). Fix / fit minor accessories as below: a) b) c) d) e) f) Clamps / Brackets for pipes and fixing of pipes on them. Prepare the cables at both the ends and fit into cable glands. bushing / WTI CT’s. Cabling on the Transformer: Carry out laying of control cables from fans. etc. etc. Fitting of terminal connectors on the bushings. Drill holes in the cable gland plates of the fan control cubicle / marshalling box / Temperature meter box as per requirement. protective relays. a) Air release plugs provided on the Main tank cover and bushing turrets.1 12. Headers and Cooler Bank pipelines. Last Updated : 31-1-2008 . I. Condenser type Bushings i) On Load Tap Changer / Diverter Switch Chamber. Fitting of sensors / probes for oil & winding temperature indicators after filling oil in the pockets provided for them.0 After installation work is over. c) Buchholz Relays. h) Upper terminal of O. 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. 12. d) Float type Oil Surge Relays (OSR).

9 16. bushings. Arrow on the oil flow indicators and the oil pumps is pointing towards the transformer tank. Minimum clearances between live parts and between live parts to earth are as per General Arrangement drawing. 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. Inspect the transformer all over and check all flanged joints and fittings for oil leakages. Release air from the inside of the transformer tank by opening all plugs / venting screws / valves on radiators.4 16.12 16.10 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.8 16. As per general prevailing practice.1 PRE – COMMISSIONING CHECKS: All equipments are mounted in position as per General Arrangement drawing of the manufacturer.11 16. Buchholz relay. Oil level in the condenser bushings. OLTC oil surge relay (float type) and gas collection pipe.Power Transformers 65 16. The thermometer pockets provided for oil and winding temperature indicators are filled with oil. OTI. The transport locks provided in equipment such as the MOLG. Arrow on the Buchholz Relays & Oil Surge Relays is pointing towards the Conservator.7 16.13 16.14 b) Winding Temperature Indicator (WTI): Fan / Fan Group – I: Oil Pump / Fan Group – II: Alarm: Trip: Last Updated : 31-1-2008 . If found necessary. etc. and tank cover until oil appears. Trip and Cooler control in the Oil and Winding Temperature Indicators.5 16. Buchholz relay contacts are not locked and these are in ‘SERVICE’ position.0 16. Oil level in the main conservator and OLTC conservator is as per the oil temperature. Close these after the above check has been carried out. 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. if provided. Setting of all the mercury switches for Alarm. re – tighten the bolts. WTI. oil flow indicators.2 16.3 16. have been removed.6 16.

Over flux.3 Testing by the Protection Wing of Over current.0 17. Winding Temperature Trip (LV). Buchholz Trip (I & II) by draining oil from the relay. temperature meter box. 16. The Transformer tank.21 17.66 Construction Manual for Sub Stations If the site and load conditions warrant. Pressure Relief Device. i) ii) iii) iv) v) vi) vii) viii) Buchholz Alarm (I & II) by draining oil from the relay. cooler control cabinet.18 16. Restricted Earth Fault (REF). Circulating Current Differential Last Updated : 31-1-2008 . Winding Temperature Trip (TV).20 16. Oil Temperature Trip. Oil temperature high alarm. etc. Master Trip relays and alarm annunciation on actual operation of the transformer mounted protective Relays and supervisory equipments. as provided are earthed. W / common. Winding temperature high alarm (TV). Neutral Displacement alarm. Winding Temperature Trip (HV). Winding temperature high alarm (LV).15 The Transformer neutral is connected to earth at two separate earth pits / electrodes which in turn are connected to the earth mat. Winding temperature high alarm (HV). Proper connections and tightness of terminal connectors provided on Bushings. Bolts & nuts of the coupling brackets of the operating shaft(s) of the OLTC have been locked. Air cell fail alarm. if provided. OLTC Conservator Low oil level alarm. as provided). if the transformer is to run in parallel with another transformer.19 16. No oil is visible in Explosion Vent sight glass. 17. OLTC drive mechanism.17 16. 17.2 Trip Alarms: Operation of the corresponding auxiliary relays. Jumpering arrangement to achieve phase matching. i) ii) iii) iv) v) vi) vii) Main Conservator Low oil level alarm. V. 16. marshalling box. OLTC Surge Relay (U.16 16. Earth fault. cooler bank.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. Setting of overload / protection relays / MCBs for fans & pumps and for OLTC motor as per their rating. higher settings of the winding temperature alarm & trip contacts may be adopted for which the manufacturer’s recommendations are to be followed.

There should be no electrical operation of the OLTC with handle inserted. Operation of stand by fans / pumps on failure of each fan / pump.7 17. b) c) d) e) f) Last Updated : 31-1-2008 . Direction of rotation of fans and pumps. Manual operation of OLTC: a) b) Operate by handle from tap no. “Stand by Pump Fail: Group – 1 & 2”. 1. supply to the Cooler Control Cubicle (CCC) / Fan Control Cubicle (FCC) / Marshalling Box. “Pump Fail: Group – 1 & 2”.9 17. Observe any abnormal sound during this operation.C. etc. such as “Fan Fail: Group – 1 & 2”. Confirm functioning of electrical limit switches at extreme tap positions. as provided. alarm annunciations. Operation of fans / oil pumps as per settings made in the winding temperature indicators as per para 16.6 17. Verify the reading of Tap Position Indicator (TPI) on Remote Tap Changer Control (RTCC) panel on all the tap positions. Step by step operation of the OLTC (only one tap should change in one pulse or with continuous pulse).11 c) d) e) 17.10 17.. 17. Testing of alarm annunciations. etc. Never start this OLTC operation from extreme tap positions. 1 to the maximum tap position & back to tap no. This may be checked for operation of each Master Trip Relay for 2 or 3 protective relays.8 17. RTCC Panel.14. Phase sequence of the A.5 17.1 from local and from remote.. 17. “Stand by Fan Fail: Group – 1 & 2”. supply to the OLTC drive mechanism. Transformer Differential protection relays. i. as provided in the RTCC Panel. Operate On Load Tap Changer (OLTC) from tap no.Power Transformers 67 protection. Check tripping of MCB in OLTC Drive mechanism by pressing “Emergency Push Button” from local and from RTCC Panel. associated Master Trip relays. 1 to the maximum tap position & back to tap no. Lamp indications on RTCC Panel for fans and pumps.C. Confirm functioning of mechanical locking at extreme tap positions.e..12 Electrical operation of OLTC: a) Operation of handle interlock. Check phase sequence of the A. Check functioning of operation counter.4 Tripping of HV circuit breaker & inter tripping of LV circuit breaker on operation of Master Trip Relays. “Cooler Control Supply Fail”.

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

12. Min. LV – Earth. Property of Oil Highest Voltage of Equipment (kV) < 72. measurement of Capacitance and Tan δ of condenser bushings and transformer windings for reference. Oxidation Stability of inhibited oil (i) Induction Period (hours) Similar values as before filling Last Updated : 31-1-2008 . Flash Point (ºC).89 0.1 6 80 27 140 -6 35 0.4 0.015 0.5 72. Breakdown Voltage (kV). testing of TV winding by giving 3 – phase supply to HV. Neutralization value (mg KOH / g). Interfacial Tension (mN / m). 8. It is not advisable to carry out this test when the relative humidity is above 75%. between HV – Earth. The top oil temperature is to be recorded. Oxidation Stability of uninhibited oil (i) Neutralization Value (mg KOH / g). 3. and 60 sec. HV – LV. Appearance 2. 5.010 6 80 27 140 -6 35 0. Winding resistance measurement of all three phases of HV (at Tap no. Min. Min. Max. Water Content (ppm). Max. 13. 10.5ºC (g / cm3). The top oil temperature is to be recorded. 1. 7.03 0.89 0. No. Subject to availability of testing instrument. 9. Max. 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. Max. j) In case of tertiary winding where two terminals have been brought out.89 0. TV – Earth. The top oil temperature is to be recorded.03 10 10 10 0. Dielectric dissipation factor at 90ºC and 40 Hz to 60 Hz. Pour point (ºC). Dissolved Gas Analysis Viscosity at 27ºC (cSt). HV – TV & LV – TV using 5 kV megger.1 6 80 For Reference 27 140 -6 35 0.5 to 170 > 170 Clear.03 0.4 0. LV and TV windings.4 0. The limits for unused mineral oil filled in New Power Transformer as recommended in Table – 1 of the above Indian Standard are given below.015 0. Max. (ii) Sludge (percent by mass). 6. Max. Testing of transformer oil. Insulation resistance measurement (meggering) and recording the readings for 15 sec. 11.Power Transformers 69 be any break in the current during tap change which is indicated by the sudden deflection in the multi – meter reading. S. HV – TV & LV – TV using turns ratio measuring instrument. Checking of Vector Group of the transformer. then shorting each LV phase with neutral one by one and measuring open delta voltage and closed delta current. 1). Min. Transformer Turns ratio measurement between HV – LV.1 k) l) m) n) o) p) 14. Density at 29. Max. Resistivity (90ºC) × 1012 (ohm – cm). The 60 second value shall be taken as the reference value for future comparison. Max. free from sediments and suspended matter 0. 4.

17. 6.70 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. Manufacturers recommend that transformer be kept on no load for 24 hours.010 6 80 6 80 For Reference 6 80 S. No. Appearance 2.7 18.0 Last Updated : 31-1-2008 . Then take load on the transformer. Min. 4.5ºC (g / cm3).5 18. 7.8 19. This may be checked for operation of each Master Trip Relay for 2 or 3 protective relays. the operation of the OLTC is to be checked by increasing the tap position upto the tap corresponding to the system voltage. Max. The limits as recommended in Table – 1 of IS 1866: 2000 are also given below. During this period observe the temperature rise of the oil & winding. Max.89 0.4 18. Dielectric dissipation factor at 90ºC and 40 Hz to 60 Hz.03 10 10 10 0. For operation and maintenance of Power Transformers.15 18.1 The results of all the above tests are to be recorded for future reference. Transformer is to be charged at tap no. 8. CHARGING OF TRANSFORMER: Check the tripping of HV circuit breaker & inter tripping of LV circuit breaker on operation of Master Trip Relays.015 0. 2.89 0. After re – charging. Breakdown Voltage (kV). Water Content (ppm). tap position of the transformer is to be fixed according to HV side voltage available. Recharge the transformer at Tap no. After charging. Max. 2 otherwise transformer may trip on differential protection due to high magnetizing inrush current. 1.6 18. De – energize the transformer and check the Buchholz relay for any collection of air / gas.3 18. Tap position (same voltage ratio) should also match with the transformer already in service in case of parallel operation. Min.5 to 170 > 170 Clear.0 18.03 0. 5. Neutralization value (mg KOH / g).015 0. Max. free from sediments and suspended matter 0.89 0. Dissolved Gas Analysis Other tests as prescribed in the Operation and Maintenance Manual of the Manufacturer. 18.5 72. the “MAINTENANCE MANUAL FOR POWER TRANSFORMERS” of RVPN (erstwhile RSEB) should be followed. r) Density at 29.2 18. 3.03 0. Property of Oil Highest Voltage of Equipment (kV) < 72. Resistivity (90ºC) × 1012 (ohm – cm).

wherever required.0 2.2 3. This should be done through cold bending using a bending machine only. erect the poles on the base channel. Level the top of the already erected supporting structure(s) and check their verticality.6 2.3 3.CHAPTER – 6 CIRCUIT BREAKERS 1. In case of CBs with common base channel but in which the poles are received separately.2 2. b) Pull the moving contact rod of each interrupter manually towards ‘OPEN’ position during which operation appreciable force should be encountered. The SF6 gas should be filled in one pole at a time to ensure that gas is filled in all the three poles. Erection of Circuit Breaker Poles: In case of CBs received with poles already fitted on a common base channel. Installation & Commissioning Manual of the Manufacturer. c) Reconnect the linkage of the individual pole to the operating lever. if required.4 1. Erect the middle pole first followed by the side poles. by opening the cover of the pipe connection and pressing the non – return valve. tested and commissioned as per the instructions given in the Erection.0 3. centering and grouting. The services of the Manufacturer’s Erection & Commissioning Engineer may be utilized wherever required. and the support columns if provided. 1. Erection of Supporting Structures: Assemble the supporting structure(s) if the members are received in loose condition. check that there is positive pressure of the SF6 gas in the breaker poles.2 1. erect the base channel along with breaker poles on the supporting structures. shall be done such that there is no flaring of the ends of the pipe.1 2. Release the moving contact rod suddenly. Erect the supporting structure(s) on the foundation and carry out their levelling. In case of SF6 Circuit Breakers. check the vacuum in the individual poles as follows: a) Remove the linkage of the individual pole from the operating lever. shall be done in a manner such that the inner diameter of the pipe is not reduced. In case of Vacuum Circuit Breakers. Preparation & Checking of the Circuit Breakers Poles: Clean the insulators of the breaker poles and check for cracks in the insulators. Only a proper pipe – cutting tool shall be used.1 4.1 GENERAL INSTRUCTIONS: The circuit breakers are to be erected.0 1. The procedure / steps generally followed for erection of Circuit Breakers are given below. Bending of compressed air piping. It should return automatically to ‘CLOSED’ position with a loud metallic noise.3 1.0 4.3 4.2 Last Updated : 31-1-2008 . Cutting of the pipes.5 1. first erect the base channel on the supporting structure(s) and carry out levelling. Thereafter.1 3.

3 7.2 4. erect the operating mechanism on the supporting structure / base channel as provided.0 6. erect the CB poles on the supporting structures.2 Last Updated : 31-1-2008 . erect the CB poles on the operating mechanisms. first erect the support columns on the supporting structures. levelling and grouting.3 4. In case of other types of CBs.4 4. Connect the SF6 gas pipeline to one pole & fill SF6 gas in the pole up to about 2 kg / cm2. 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.3 In case of CBs in which the poles are to be erected on the operating mechanism. or on the common base channel. Place the air compressor.4 6.72 Construction Manual for Sub Stations 4. In other cases. erect it on its foundation and carry out its centering. Check for leakage of SF6 gas in the pole and in the SF6 gas pipeline.1 5.1 7. Thereafter erect the arc chamber assemblies on the support columns of individual phases. Fit the pre – insertion resistors and voltage grading capacitors. For Gang Operated Circuit Breaker: Connect the operating shaft / rod between the poles and between the first pole and the mechanism.5. or as applicable.1.5.1 7.3 5. erect it on its foundation and carry out its centering. In other cases.1 6. if provided separately.8 5. on the arc chambers.0 5. if any.7 4. 4. Check the verticality of the erected poles of the CBs and correct the same wherever required. or on the common structure.1. Attend to the leakages.2 6. the operating mechanism is generally received mounted on the assembled structure. In case of CBs with horizontal arc chambers. on its foundation & carry out its centering. if provided. In case of circuit breakers up to 33 kV.0 7. erect the control cubicle on the supporting structure / base channel as provided. IMPORTANT: DO NOT CHANGE OR ADJUST THE LENGTH OF THE OPERATING SHAFT / ROD. In case of ground mounted operating mechanism. Erection of Operating Mechanism.6 4.2 5. as applicable. Accessories & Associated Equipment: In case of ground mounted control cubicle. Fit the terminal connectors on the three poles of the breaker. levelling and grouting.1 4. Thereafter. Fit the protective covers for operating shaft / rod.5. first erect the operating mechanisms on the supporting structures and carry out levelling. Erect the operating mechanism / operating drive on the supporting structure of the designated phase. or on all the three individual phases / poles.

2 8.3 Last Updated : 31-1-2008 . Check for leakage of SF6 gas in the poles and in the SF6 gas pipeline.9 7.9 ensures that SF6 gas is filled in all the three poles. supply to the air compressor and check direction of rotation of air compressor motor.11 7. The gas pressure in the first pole will fall. Check phase sequence of the A.2.2. 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.2.1.6 7.) and attend if any leakage is detected.1 7. if any. brazing.1.5 8. Check for leakage of SF6 gas from all the points (e. Attend to the leakages. Circuit Breakers having Pneumatic Operated Mechanism: Fabricate the compressed air pipeline as per pipe layout drawing & clean it. Check operation of the alarm and lockout contacts provided in the density monitor during SF6 gas filling. cementing on insulator & metallic joints. Ensure that the alarm and lockout contacts are in normal condition after SF6 gas filling.1. Finally fill SF6 gas in all the three interconnected poles up to prescribed rated / filling pressure. provided in the density monitor.1.1.2 7.4 7. if any.8 7.4 to para 7.1.C.2. Check and top up oil in the air compressor. joints. couplings. Attend to the leakages.1 8.5 7. if any. Also check that the V – belt is at the correct tension.2 7. The setting and operation of the lockout contacts (closing) and the alarm contact (opening).1. Fill SF6 gas in each pole one by one up to about 2 kg / cm2. Fill SF6 gas up to prescribed rated / filling pressure in each pole one by one.4 7. The procedure from para 7. etc. are checked during SF6 gas filling.3 Fill SF6 gas in the pole up to the prescribed rated / filling pressure.g.1..7 7. Check for leakage of SF6 gas in the second pole.Circuit Breakers 73 7. Fill the SF6 gas in the two poles simultaneously up to the prescribed rated / filling pressure.10 7. one end of the pipeline is connected to the air compressor and the other end is plugged.2. The filling pressure should correspond to the ambient temperature at the time of filling as per the chart given in the manufacturer’s manual. Fit the pipeline as per drawing. The filling pressure should correspond to the ambient temperature at the time of filling as per the chart given in the manufacturer’s manual. Connect the SF6 gas pipeline to the second pole. Connect the SF6 gas pipeline to the third pole.1. The pipeline is first cleaned by passing a mulmul cloth through it with the help of a wire. A small air pressure is injected in the pipeline and then suddenly released by removing the plug so that the pipeline is flushed. 7.1.0 8. Check for leakage of SF6 gas in the third pole.1. Ensure that the alarm and lockout contacts are in normal condition after SF6 gas filling.3 7. Thereafter.

Adjust the pressure settings if required. “Low Air Pressure Alarm” & “Compressor Stop”. as per manufacturer’s recommendations. check operation of pressure switches and verify their settings for “Oil Pump Start”.2 9. as and when required. “Low Oil Pressure Alarm”. check operation of pressure switches and verify their settings for “Low Oil Pressure Lockout”. “Auto Reclose Blocking”.1 9. Switch off the A. Top up oil..8 9. couplings. in the storage tank(s) up to the fill mark. Check operation of safety valve and verify its setting. Fit the prefabricated hydraulic oil pipeline as per drawing. Check the auto / manual operation of air compressor. Check phase sequence of the A. control blocks.6 9.C. brazing. Start the compressor in the manual mode and build up pressure. “Auto Reclose Lock out”. Check the auto / manual operation of the oil pump. supply to the oil pump motor and check its direction of rotation. 8. During falling pressure. Pressurize the compressed air pipeline to the rated pressure. “Low Oil Pressure Alarm” & “Oil Pump Stop”.5 9. Check for oil leakage from all the points (e.9 9. During the rising pressure.10 Last Updated : 31-1-2008 .. “Auto Reclose Blocking” & “Low Air Pressure Lockout”. If the safety valve does not operate even when the prescribed pressure is exceeded.g. Drain air so as to maintain normal pressure in the storage tank(s). and “Low Oil Pressure Lockout”. to maintain oil level in the storage tank. Build up pressure in the hydraulic oil pipeline.6 8. 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. etc. C. Open the drain valve on the air storage tank such that air is released slowly. couplings. joints. stop the oil pump motor and adjust the setting to the required value and re – verify this setting.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. for “Low Air Pressure Lockout”. Start the oil pump motor and release air from the venting screw(s) provided. stop the air compressor and adjust the setting to the required value and re – verify this setting. check the operation of pressure switches and verify their settings. etc. Start the oil pump in the manual mode and build up pressure.4 9. joints. Fill hydraulic oil. “Auto Reclose Lock out”. During the falling pressure.74 Construction Manual for Sub Stations 8.3 9. check the operation of pressure switches and verify their operating and differential settings.7 9.5 8.0 9.7 8. Open bypass valve to reduce the oil pressure.) and attending to the leakages if detected.) and attend to the leakages if detected. of the designated grade as supplied with the Circuit Breaker. Check operation of safety valve and verify its setting.8 9. supply to the compressor. “Low Air Pressure Alarm”.g. During increasing pressure. for “Compressor Start”. If the safety valve does not operate even when the prescribed pressure is exceeded. as per manufacturer’s recommendations. brazing. Open bypass valve to reduce the oil pressure to normal.

iii) Air filter is clean. m) Auxiliary contacts as required for various control circuits.0 11. Adjust the setting of the limit switch if required. Y & B) and control cubicle. a) DC positive & DC negative for local operation. iii) Density Monitor and control cubicle. f) Protection trip signal. iv) Control cubicle and Control & Relay Panel. Dress and fix the cables in cable trays / trenches / supports / brackets. ii) Compressor and control cubicle.2 11. PRE – COMMISSIONING CHECKS: Check the following in the Air Compressor: i) Oil level is upto the mark.5 11.4 10.Circuit Breakers 75 10. then discharge the spring as per instructions given in the manufacturer’s manual.0 10. j) Air pressure / Oil pressure / Spring charging limit switch contacts for auto reclose blocking. Discharge the spring as per directions in the manufacturer’s manual.2 10. Carry out slow mechanical operation (closing and tripping) of Circuit Breaker as per procedure prescribed by the manufacturer. Take all the precautions mentioned in the manufacturer’s manual. d) Remote closing signal. g) Trip circuit supervision. i) Auto Trip / Spring Charged Lamp indication. 10.4 12. iii) V – belt is properly tensioned. v) Control cubicle and bay marshalling kiosk.0 12. l) Contact for annunciation of pole discrepancy trip alarm. e) Remote tripping signal. ii) Oil colour is not black.3 11. If it is not fully discharged. Cabling & Wiring: Carry out laying of cables between the following: i) Operating mechanisms of individual phases (R. h) ON / OFF indications (Lamp & Semaphore).1 11. Manually charge the closing spring and check electrical limit switch. mechanical latches and stopper(s) as provided. Connect the cables as per schematic diagram of the circuit breaker. The following typical connections are made at the circuit breaker end. k) Contacts of pressure switches for annunciations of low SF6 gas / air / oil pressure alarms & lockout conditions and for loss of N2 pressure.1 Last Updated : 31-1-2008 . Fix the cables in cable glands and then fix the cable glands on cable gland plates in the respective equipment. b) DC positive for remote closing.3 10. Charge the spring electrically and verify the operation of the limit switch. if applicable.1 Circuit Breakers having Spring Operated Mechanism: ENSURE THAT THE CLOSING SPRING IS FULLY DISCHARGED. c) DC positive for remote tripping.

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.6 12.0 13. SF6 gas / hydraulic oil / air pressure lockout and loss of N2. control cubicle. in the C&R Panel for CB OPEN.2 12. CLOSED. Check settings of air / oil pressure switches.5 Check SF6 gas / hydraulic oil / air leakages.76 Construction Manual for Sub Stations 12. base channel.18 12. remote and protection. as applicable.13 12. as applicable. It should damp the speed of the Circuit Breaker at the end of both closing and tripping operations. Check closing and opening operation of circuit breaker from local.9 12. as applicable.16 12. Check earthing of the poles. and its alarm annunciation in the C&R Panel.19 12.4 12.11 12. The oil level should be between the maximum & minimum level marks.14 12.3 12. as applicable. Check operation of pole discrepancy relay.8 12. otherwise.12 12. if provided. The breaker should close and then trip and should not close again.10 12. Lubricate all the moving parts and the pins in the operating mechanism. Check resistance of closing and tripping circuits. Check and adjust the resistance in the closing / tripping coil 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. compressor and structure(s).7 12. Check clamping of the pipe line for SF6 gas / hydraulic oil / air. Check closing of Circuit Breaker through auto – reclose scheme.17 12. Check the pressure of SF6 gas / hydraulic oil / air in the circuit breaker. as applicable. as applicable. 12. if required.20 13. Check functioning of operation counter.15 12. operating mechanism. Check functioning of space heater and internal illumination circuits. Confirm that the correct pole of the Circuit Breaker has operated. AUTO TRIP and SPRING CHARGED conditions. top up with oil. if provided.1 Last Updated : 31-1-2008 . Check alarm annunciations in the C&R Panel for low SF6 gas / hydraulic oil / air pressure alarm. and attend if required. Check operation of dash pot / damper. Check the oil level in the oil storage tank(s) of all the three poles of CBs with hydraulic oil operated mechanism. Check the Trip Circuit Supervision circuits in both CB open and closed conditions by removing the wires of the tripping circuit. Check lamp and semaphore indications. Check operation of anti – pumping / hunting relay by giving continuous closing and tripping signals simultaneously.

Test the operation of the CB with the emergency tripping arrangement. Last Updated : 31-1-2008 .4 The vacuum interrupters should withstand the applied voltage. 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. check the vacuum as given at para 3. apply the voltage as given below across the upper & lower terminals of the VCB for 60 seconds. Since the above facility is not available.Circuit Breakers 77 13.2 Measure Closing (C). if provided. (a) (b) 33 kV CB 11 kV CB 70 kV 28 kV 13.3 13.3 above. Opening (O) and Close – Open (CO) operation timings of the breaker with CB Timer or CB Analyser.

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

0 2.CHAPTER – 7 ISOLATORS 1. Fit the male and female contact arms on the polycone insulators / insulator stacks in case of single break Isolator. Fix the arcing horns (make before & open after the main contacts) or corona rings. the quantity will be nine. Check the operation and final adjustment / alignment of all the three phases of main Isolator for smooth. In case of double break Isolator. Carry out adjustment / alignment of individual phases for smooth opening and closing and proper making of contacts. Erect the 3 nos. including fixing of hardware for interlocking with earth switch wherever provided. moving contacts are fitted on the polycone insulators / insulator stacks. for erection of the Isolator and operating mechanism(s). Fit the main operating down pipe to operating mechanism for the Isolator. if required. 6 nos.10 1.7 1.16 2.6 1. as applicable. wherever provided.11 Fit the inter – phase connecting pipes between the rotating parts of the base frames of the individual phases.14 1. Fit the fixed contacts of earth blades in case of Isolator with Earth Switch.13 1. synchronized and complete operation as one unit.12 1.5 1. 1. Erect the above assemblies on the rotating parts of the base frames. 1. Fit the terminal connectors on the Isolator. Fix the link pipes on the rotating parts of the base frames of the individual phases.2 Last Updated : 31-1-2008 . there will be six polycone insulators / insulator stacks whereas for double break Isolators.8 1.9 1. For single break isolators. as applicable.2 1.15 1. base frames of individual phases on the structure(s).3 1. ERECTION OF EARTH SWITCHES: Fix the earth blade mounting arrangements on the base frames of all the three phases. Clean and assemble the polycone insulator / insulator stack. Adjust the mechanical end stoppers on the base channel for both the closed and open positions. Fit the operating mechanism box for the Isolator. Fit the moving contact (earth blade) of the earth switches and counterweights.1 ERECTION OF ISOLATORS: Level the already erected structure(s) and carry out minor fabrication works. fixed contacts and 3 nos. Carry out levelling and centering of the base frames.0 1.4 1.1 2.

h) Contact for annunciation of pole discrepancy trip alarm.9 2. Check the operation and final adjustment / alignment of all the three phases of the earth switch for smooth. iii) Operating mechanism and bay marshalling kiosk. a) DC positive & DC negative for local operation.80 Construction Manual for Sub Stations 2. c) DC positive for remote closing. and that main Isolator does not operate if the earth switch is closed. d) DC positive for remote opening. Cabling & Wiring: Carry out laying of cables between the following: i) Operating mechanisms of individual phases (R. f) Remote opening signal.0 3. 2. g) OPEN / CLOSE indications (Lamp / Semaphore). e) Remote closing signal.1 3.1 4. OPERATING MECHANISM: Carry out the adjustment and setting of auxiliary switches.4 2. Fit the earth bonds and other accessories as provided. Fit the operating mechanism box for the earth switches. synchronized and complete operation as one unit. are made at the isolator and earth switch end. including fixing of hardware for interlocking with main Isolator. The following typical connections. Dress and fix the cables in cable trays / trenches / supports / brackets. i) Auxiliary contacts as required for various control circuits. Carry out the adjustment of mechanical end stoppers for both the CLOSED and OPEN positions.8 2. Carry out the adjustment of limit switches in CLOSED and OPEN positions of Isolator in case of motor operated mechanism.4 4.2 3. Connect the cables as per schematic diagram of the isolator and earth switch.0 4.2 4.6 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.10 3. b) Interlocking supply.3 4.4 Last Updated : 31-1-2008 .5 2. ii) Operating mechanism and Control & Relay Panel. Carry out the adjustment of interlocking coil and plunger in CLOSED and OPEN positions.7 2.3 Carry out the operation and adjustment / alignment of earth switch of each phase for smooth opening and closing and proper making of contacts. as applicable. Fit the main operating down pipe to operating mechanism for the earth switch. Carry out the adjustment of mechanical end stoppers for the OPEN position of earth switch. Fit the inter – phase connecting pipes between the earth switches of the individual phases. Fix the cables in cable glands and then fix the cable glands on cable gland plates in the respective equipment. Y & B) in case of individual phase operating mechanism.3 3.

Check operation of Isolator and earth switch for following: i) Smooth operation. supply to the motor and check direction of rotation of isolator.0 6. if provided. Check operation & verify setting of timer for Isolator operation and pole discrepancy. Check local and remote electrical operation of the isolator.2 6. for Bus Isolators. as provided.2 Last Updated : 31-1-2008 .9 5. Measure the Contact Resistance of 400 kV Isolators in the CLOSED position. Check earthing of the operating mechanism. PRE – COMMISSIONING TESTS: Measure the insulation resistance with 5 kV megger of each phase to earth in the Isolator CLOSED position. Check functioning of space heater and internal illumination circuits in the motor operated mechanism. Check earthing of the main Isolator and earth switch. Check operation of electrical limit switches in motor operated mechanism. iii) Complete opening of contacts in open position. if applicable.5 5. 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. ii) Complete insertion and making of contacts in close position.0 7. 5. in the C&R Panel for Isolator and earth switch OPEN and CLOSED conditions.8 5.1 PRE – COMMISSIONING CHECKS: Lubricate all the moving parts and the pins of the Isolator & earth switch and in the operating mechanism.1 7. as applicable. Also check operation of voltage selection relay. Check operation of the electrical emergency opening arrangement.10 5.3 6.C. Check phase sequence of the A. Check operation & verify setting of overload relay / MCBs for motor.Isolators 81 5.0 5.6 5. Check operation of interlocking coil in the Isolator and earth switches. v) Setting of end stoppers in close and open conditions.4 5.3 5.4 7.11 6.7 5.1 6.2 5. if provided. iv) Functioning of mechanical interlock between main Isolator and earth switch. vi) Operation of auxiliary switches. Check earthing of moving parts such as operating handles of isolators. if provided. if applicable. including interlocking between main isolator and earth switches. which should be earthed through flexible earthing connectors. Keep the isolator in half closed position before checking the phase sequence. Check lamp / semaphore indications.

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Core 2 PS / 5P20 Over current & Earth fault Protection 3. Core 2 5P20 Over current & Earth fault Protection 3. Core 3 0.5 Metering: Indication & Energy Meter 4. Core Number Accuracy Class Purpose 11 kV Feeders CT Ratio: 100 – 200 – 400. 1. 1. Core 3 0. 1. Core 2 0.2 Metering: Main Energy Meter 5. 125 – 250 – 500.0 Metering: Indication 4. No.2 Last Updated : 31-1-2008 . Core 3 0.1 GENERAL INSTRUCTIONS: While erecting the Current Transformers. Core 1 PS Differential Protection 2. Core 4 PS / 5P20 Bus Bar Protection 132 kV side of 132 kV class Transformers CT Ratios: 60 – 120 – 240. 1200. Core 1 5P20 Over current & Earth fault Protection 2.5 Metering 11 kV side of 132 kV Class Transformers CT Ratios: 200 – 400 – 800. 250 – 500. Core 5 0. 250 – 500. Core 3 0. Core 4 0. Core 1 5P20 Over current & Earth fault Protection 2. 1. The different cores of the secondary winding of the Current Transformers are used for the following purposes.5 Metering: Indication & Energy Meter 33 kV side of 132 kV Class Transformers CT Ratios: 150 – 300 – 600. Core 1 PS Differential Protection 2. 1. Core 2 PS / 5P20 Over current & Earth fault Protection 3.CHAPTER – 8 CURRENT TRANSFORMERS 1.5 Metering 33 kV Feeders CT Ratios: 60 – 120 – 240. Core 1 PS Differential Protection 2. it must be ensured that the P1 terminal is towards the Main Bus side. The secondary windings are rated for 1 Amp or 5 Amp. 1. 125 – 250 – 500. Core 2 0. Core 2 5P20 Over current & Earth fault Protection 3. 250 – 500.2 Metering: Check Energy Meter 132 kV Feeders at 132 kV GSS CT Ratios: 100 – 200 – 400. Core 1 PS Distance Protection 2.5 / 1.0 1. 1. Core 3 0. Core 2 PS / 5P20 Over current & Earth fault Protection 3.5 Metering: Indication & Energy Meter 132 kV Feeders at 220 kV GSS CT Ratios: 100 – 200 – 400.5 Metering: Indication & Energy Meter 1. Core 1 PS Distance Protection 2.

84 Construction Manual for Sub Stations No. Core 3 0. Core 4 PS Bus Bar Protection (Main Zone) 5. Core 1 PS Differential Protection Main – 1 / Distance Protection Main . Core 3 0. Over current. 3. Core 2 PS Distance Protection Main – 2.1 2. 1. Core 5 PS Bus Bar Protection (Check Zone) 220 kV side of 400 kV class Transformers CT Ratio: 500 – 1000 – 2000. Earth fault and LBB Protections 3. 400 – 800. Over current. Core 5 PS Bus Bar Protection (Check Zone) 400 kV Bays CT Ratio: 500 – 1000 – 2000. 2.1 2. Core 4 PS Bus Bar Protection (Main Zone) 5. Earth fault and LBB Protections 3. Core 4 PS / 5P20 Bus Bar Protection 220 kV Feeders CT Ratios: 200 – 400 – 800.5 Metering 4. Core 3 0. 400 – 800. 1. 1. Core 5 PS Bus Bar Protection (Check Zone) 220 kV side of 220 kV class Transformers CT Ratio: 150 – 300 – 600. Core 2 PS / 5P20 Over current & Earth fault Protection 3. Core 4 PS Bus Bar Protection (Main Zone) except for CTs in Tie CB Bay 5. 1.5 Metering 4. Over current. 1. Core 1 PS Differential Protection 2. Core 2 PS Over current. Core 1 PS Differential Protection Main – 1 / Distance Protection Main – 1 2. Earth fault and LBB Protections 3. 1. Core 5 PS Bus Bar Protection (Check Zone) except for CTs in Tie CB Bay 1.5 Metering: Indication & Energy Meter 4. Earth fault and LBB Protections 3. Core Number Accuracy Class Purpose 132 kV side of 220 kV class Transformers CT Ratios: 150 – 300 – 600.5 Metering 4. Core 1 PS Distance Protection Main .3 Ferrule markings as mentioned below are generally used as prefix for indicating the wires of different cores of the Current Transformers: S.5 Metering 4. Core 2 PS Differential Protection Main – 2 / Distance Protection Main – 2. Core 3 0. Core 3 0. 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 . No. Core 1 PS Differential Protection 2. Core 4 PS Bus Bar Protection (Main Zone) 5. Core 2 PS Differential Protection Main – 2 / Distance Protection Main – 2. 250 – 500. 4.

6 Last Updated : 31-1-2008 .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.0 3. Y & B phases) to the Marshalling Kiosk / Junction Box.5 3.4 2.Current Transformers 85 2.5 3. Clean the insulator of the Current Transformer. Connect all the cores of the secondary winding from the secondary terminal box of Current Transformers (R. Fix the cables in cable glands and then fix the cable glands on cable gland plates in the respective equipment.0 2. Erect the Current Transformer on the structure. for erection of the Current Transformer. The secondary windings of different phases of Current Transformers are generally star connected. Fit the terminal connectors on the Current Transformer.3 3.4 3. Dress and fix the cables in cable trays / trenches / supports / brackets.2 3. Cabling & Wiring: Carry out laying of cables from secondary terminal box of the Current Transformer to the bay Marshalling Kiosk (MK) / Junction Box. if required.3 2. Measure the IR values of primary terminals to earth with 5 kV Megger.2 2. A typical wiring connection for Core – 1 of Current Transformers in the Bay Marshalling Kiosk / Junction Box is shown below: 2.1 3.

4 4. 4.0 Last Updated : 31-1-2008 . 33 KV AND 11 KV INSTRUMENT TRANSFORMERS (CT’s. Check that all the spare cores of the secondary winding of the Current Transformer have been shorted and earthed. for each core at a time while shorting all the other cores in the Current Transformer. ELECTROMAGNETIC PT’s AND CVT’s)” of RVPN (erstwhile RSEB) should be followed.3 5.0 4.3 4. etc.6 5. Check that the star / neutral formation of the secondary windings of the three phases of the Current Transformers has been made correctly. Y. Verification of polarity between the primary winding and all the secondary windings. Check that the neutral point of the secondary windings has been earthed in the Marshalling Kiosk / Junction Box. Verification of all the current ratios between the primary winding and all the secondary windings.0 5.5 5. For operation and maintenance of Current Transformers. Checking of use of the secondary windings as per their accuracy class / knee point voltage / burden for protection / metering.4 5.86 Construction Manual for Sub Stations 4. such as meters and relays.2 4. primary winding to all the secondary windings with 5 kV Megger and all secondary windings to earth with 500 V Megger. B) by applying current through primary injection in each Current Transformer and measuring the current in the respective equipment in the control room. the “MAINTENANCE MANUAL FOR 132 KV. PRE – COMMISSIONING TESTS (By Protection Wing): Measurement of insulation resistance between primary winding to earth. Checking of continuity of the current circuit of the secondary windings and the verification of phases (R.2 5..5 4. 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.6 6.1 5. Check the earthing of the Current Transformers and Marshalling Kiosk / Junction Box. Testing of knee point voltage of all the protection cores.

0 2. Core 2 3.4 2.CHAPTER – 9 CAPACITOR VOLTAGE TRANSFORMERS (CVT) / POTENTIAL TRANSFORMERS (PT) 1.2 A ferrule ‘E’ is generally used as prefix of the ferrule markings for indicating the wires of different cores of the VTs. Sl. Core 1 2.1 2. The term Voltage Transformer (VT) is used to cover both PT and CVT.5 Last Updated : 31-1-2008 .5 0.2 2.5 3P 0. Measure the IR values of primary terminal to earth with 5 kV Megger. Core 2 220 kV 1.5 0.0 1. generally referred to as Potential Transformers (PT).3 1. Assemble the different units of the same serial number of the CVT. The different cores of the secondary winding of the VT are used for the following purposes. Clean the insulators of the VTs. and Capacitor Voltage Transformers (CVT) are used for protection and metering. Core 2 3. The CVT or its individual units should be kept shorted and earthed to prevent shock from accumulated charge. 2. Core 2 400 kV 1. Core 3 1.1 GENERAL INSTRUCTIONS: Electromagnetic Voltage Transformers.No. if required. Core 1 2. This shorting may be temporarily removed for testing. ERECTION: Carry out levelling of already erected structure(s) and minor fabrication work.5 0. Core 1 2.5 3P 3P 0. for erection of the Capacitor Voltage Transformers / Potential Transformers. Core 1 2.2 3P 0.2 0.3 2. Erect the Capacitor Voltage Transformer / Potential Transformer on the structure.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. The secondary windings are rated for 110 / √3 Volts.4 Accuracy Class 3P / 0. Core 2 33 kV 1. if applicable. Core Number 11 kV 1. Core 3 132 kV 1. Core 1 2. The shorting should be finally removed before energizing the CVT.

One end of these windings must be earthed in the Marshalling Kiosk / Junction Box.2 3. Fix the cables in cable glands and then fix the cable glands on cable gland plates in the respective equipment.4 3. Y & B phases) to the Marshalling Kiosk / Junction Box. 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 . Fit the terminal connectors on the VT’s. Connect all the cores of the secondary winding from the secondary terminal box of VTs (R.88 Construction Manual for Sub Stations 2. The secondary windings of different phases of VTs are connected either in star or open delta. Dress and fix the cables in cable trays / trenches / supports / brackets.5 3.6 2.0 3.3 3.6 Fit the covers on the joints between different units of the CVT. The cores of VTs which are not used should be left open.1 3.7 3. Cabling & Wiring: Carry out laying of cables from secondary terminal box of the VTs to the bay Marshalling Kiosk / Junction Box.

PRE – COMMISSIONING TESTS (By Protection Wing): Measurement of insulation resistance between primary winding to earth. Verification of all the voltage ratios between the primary winding and all the secondary windings. Check that the temporary shorting and earthing of the CVT or its units has been removed.0 4. Check that the fuses provided in the VT secondary circuits are of correct rating and that there is proper grading of the fuses.1 5.2 PRE – COMMISSIONING CHECKS: Earth the HF Terminal of CVT. 4.6 4.4 4.2 5.1 4. 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.5 4. and all secondary windings to earth. 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. Verification of polarity between the primary winding and all the secondary windings.4 Last Updated : 31-1-2008 .Capacitor Voltage Transformers (CVT) / Potential Transformers (PT) 89 4.3 5. Check that there is no shorting in the wiring of the secondary circuit of the VTs.7 5. Check the earthing of the VTs.3 4. primary winding to all the secondary windings. if it is not used for PLCC system.0 5. Verification of use of the secondary windings as per their accuracy class / burden for protection / metering.

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

Erect the Lightning Arresters on the already prepared arrangement on the beam of the substation structures. Also. 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. 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: 1.4 2.8 3.4 4.0 1. Fit the Surge Monitor on the structure and connect it to the lowest unit of the Lightning Arrester above the base insulator.1 3.0 3.1 Last Updated : 31-1-2008 .1 2.2 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. Erect the Lightning Arresters on the already erected and levelled supporting structure(s). PRE – COMMISSIONING CHECKS: Ensure that there is appropriate clearance (Min.3 2.5 2.CHAPTER . Erection of 33 kV & 11 kV LAs: Make mounting arrangements on the beam of the already erected sub – station structures. 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. carry out fitting of the corona rings between different units.10 LIGHTNING ARRESTERS 1.1 GENERAL INSTRUCTIONS: The serial number of all the units of a multi – unit Lightning Arrester (LA) should be the same. Fit the terminal connectors on the Lightning Arresters. Fit the terminal connectors on the Lightning Arresters. Clean the insulators of the Lightning Arresters.4 2.0 4.6 2. Clean the insulators of the Lightning Arresters.3 3.0 2. if applicable. if provided. Assemble the different units of the same serial number of the Lightning Arresters. if provided. The insulated base unit should be erected in case of Lightning Arresters provided with surge monitors.3 1. as required. Fit the corona / grading ring on the top of the Lightning Arrester.7 2.2 1.

4.4 5. Measure the insulation resistance between line end of LA to earth with 5kV Megger. if applicable. Note down the initial readings of the surge counters in the Surge Monitors.2 For LAs of 132 kV class & above. Check the leakage current meters in the Surge Monitor after the Lightning Arresters are energized. and between the Surge Monitor and earth.2 6.3 4.0 5.1 5.92 Construction Manual for Sub Stations 4. PRE – COMMISSIONING TESTS: Measure the insulation resistance of individual units of the Lightning Arrester. check the tightness of the connection between the Lightning Arrester and the Surge Monitor. The reading should be well within the “green zone” marked on the scale of the leakage current meters. with 5 kV Megger.0 Last Updated : 31-1-2008 . Check the tightness of the earthing connection of the Lightning Arrester for 33 kV & 11 kV LAs.

Assemble the parts of Post / Polycone Insulators.0 2. if provided. Clean the Post / Polycone Insulators.1 PRE-COMMISSIONING CHECKS: Check the tightness of the earthing connection of the base of the Post / Polycone Insulators. Fit the clamps on the Post / Polycone Insulators.11 POST / POLYCONE INSULATORS 1. 3. 2.0 3.CHAPTER .1 1.2 1.3 1. Fit the corona ring on the Post / Polycone Insulators. Last Updated : 31-1-2008 .1 PRE-COMMISSIONING TESTS: Measure the insulation resistance between top and bottom part of the Post / Polycone Insulators with 5 kV Megger.4 1.5 1.6 ERECTION: Level the top plate of the already erected structure for Post / Polycone Insulators. if required.0 1. Erect the Post / Polycone Insulators on the already erected supporting structure.

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3 above in case the end to end return loss is not found satisfactory during testing of the PLCC Carrier Sets.3 2. ERECTION OF SUSPENSION TYPE WAVE TRAPS: Fit the hardware for fixing the Wave Trap to the suspension string assemblies of the designated phases.CHAPTER .2 1.0 2.2 2.3 For single circuit lines. the Wave Traps are generally erected on R & B phases. Fit the Wave Trap on the already erected suspension string assemblies through suitable attachment.No.5 Last Updated : 31-1-2008 .0 3.1 4. ERECTION OF PEDESTAL TYPE WAVE TRAPS: Level the top plate of the already erected structure for wave trap.3 4.0 1. Erect the polycone insulator(s) on the supporting structure. ASSEMBLY: Clean the Wave Trap and its associated equipment. Hoist the Wave Trap through lifting arrangement on the beam of the sub-station structure. Fit the tuning pot and associated equipment in the Wave Trap.2 4. The Wave Traps may be required to be erected on phases different from those mentioned at para 1. Double Circuit 1.0 4.1 3. Fit the terminal connectors on the Wave Traps.2 3. S.2 and para 1.1 2. and position them correctly.4 3. 1. Erect the Wave Trap on the polycone insulators. In case three Polycone Insulators are provided for each Wave Trap and these are in parts. Fit the end covers on the wave traps. Single Circuit 2. Assemble the parts of the Polycone Insulators.1 GENERAL INSTRUCTIONS: The Wave Traps are erected as below.12 WAVE TRAPS 1. For double circuit lines.3 4. 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. then the connecting plate between the joints of the parts of the Polycone Insulators is also fitted.4 2.4 4. the Wave Traps are generally erected on the Y phase of both the circuits. if applicable.

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Check earthing of the LMU / LMDU. 2.4 2. designated Capacitor Voltage Transformers (as per coupling requirement) for fixing of Line Matching Unit (LMU) / Line Matching Distribution Unit (LMDU). Fit the co – axial cable on the LMU and LMDU.1 2. Check the tightness of connections in 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. Prepare the ends of the co – axial cable and fix the connectors at the ends.2 3.0 3.1 GENERAL INSTRUCTIONS: Open the earthing of the HF terminal of the CVTs and the LMU / LMDU before testing the system.5 Last Updated : 31-1-2008 .6 2.0 2.3 3.1 3.3 2. Lay the co – axial cable between LMU and LMDU. ERECTION: Make arrangements / carry out minor fabrication work (if required) on the supporting structure of the 2 nos.0 1.5 2.CHAPTER . 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). Connect the HF terminal of the Capacitor Voltage Transformer to the HF terminal of the LMU / LMDU.7 3. These CVTs shall be of the same phase on which the wave traps have been / are to be erected.4 3.13 LINE MATCHING UNIT (LMU) / LINE MATCHING DISTRIBUTION UNIT (LMDU) 1. Earth the LMU / LMDU by connecting the earthing terminal to the earth mat.2 2. Visual check for any dry solder in the circuits of the LMU / LMDU. Fit the LMU / LMDU on the already erected structure.

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1 3.1 GENERAL INSTRUCTIONS: DURING ERECTION WORK ON CAPACTIOR BANKS. ERECTION OF CAPACITOR BANKS: Erect the post insulators on the already erected structure(s). Measure the IR values to earth of Series Reactors with 5 kV Megger.2 Last Updated : 31-1-2008 .2 3.0 2.6 4.4 3. Series Reactors and Residual Voltage Transformers / Neutral Current Transformers. erect the frame of the third phase after erecting post insulators on the frame of the second phase. ERECTION OF STRUCTURES: Assemble the structures for the Capacitor Banks.3 3.0 3. Refer to instructions in Chapter–11 for erection of post / polycone insulators.CHAPTER . Erect the frame of the second phase after erecting post insulators on the frame of the first phase. ERECTION OF ASSOCIATED EQUIPMENT: Clean the insulators of the Series Reactors and Residual Voltage Transformers / Neutral Current Transformers.2 2. centering and grouting.5 3.0 4. 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.0 1. In case only one structure is provided for all the three phases. Level the top of the already erected supporting structures and check their verticality.1 4. In case individual structures are provided for each phase. Erect the supporting structures on the foundation carry out their levelling.2 2. Similarly. erect the frame of each phase of the Capacitor Bank on the post insulators. In case no erection plan is provided. THE CAPACITOR SHOULD BE KEPT SHORTED AND EARTHED TO PREVENT ELECTRIC SHOCK DUE TO ACCUMULATED CHARGE. Fit the post insulators and connecting strips for jumpering as per manufacturer’s general arrangement drawing. measure the capacitance of all the units and make phase wise combinations so that the capacitances of all the phases are balanced.1 2. if the members are received in loose condition.3 3.14 CAPACITOR BANKS 1. 1. including fitting of external fuses if provided. CAUTION: CAPACITOR BANKS SHOULD NOT BE SWITCHED ‘ON’ WITHIN 5 MINUTES OF SWITCHING OFF TO ALLOW THE CAPACITOR UNITS TO GET DISCHARGED. erect the frame of the first phase on the post insulators. Interconnect the capacitor units and phases as per manufacturer’s general arrangement drawing.

4 6. PRE – COMMISSIONING TESTS: (By Protection Wing / Capacitor Division) Measurement of capacitance of the three phases of the Capacitor Banks for verifying balancing.0 7. current transformers and isolators as per instructions in Chapter – 6 for erection of CB. Chapter – 7 for erection of isolators and Chapter – 8 for erection of CTs. Carry out pre – commissioning checks on circuit breaker.2 7.4 6. Dress and fix the cables in cable trays / trenches / supports / brackets.2 Fix the cables in cable glands and then fix the cable glands on cable gland plates in the respective equipment. 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.0 6.1 5. current transformers and isolators as per instructions in Chapter – 6 for erection of CB. Erect the associated equipments.3 5.7 6. Chapter – 7 for erection of isolators and Chapter – 8 for erection of CTs. Connect the cables as per schematic diagram of the Control & Relay Panel. Check that there is no shorting and earthing of the Capacitor Units / Banks. Series Reactors and Residual Voltage Transformers / Neutral Current Transformers. Measurement of IR values to earth of Capacitor Banks & Series Reactors with 5 kV Megger. Check healthiness and rating of fuses of units of the Capacitor bank. PRE – COMMISSIONING CHECKS: Check for proper connections of Capacitor Bank units as per manufacturer’s drawings.3 Last Updated : 31-1-2008 .1 6.4 4.0 5. 4. Marshalling Kiosk / Junction Box and Control & Relay Panel.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. Check oil level in the Residual Voltage Transformers / Neutral Current Transformers and Series Reactors (if oil filled).1 7. Erect the circuit breaker with supporting structure. Cabling & Wiring: Carry out laying of cables between the following: i) ii) Residual Voltage Transformers / Neutral Current Transformers and the Marshalling Kiosk / Junction Box. 5. viz.5 6.2 6..6 6.100 Construction Manual for Sub Stations 4. 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). Check the earthing of the structures and the equipment.8 7.5 5.

current transformers and isolators as per instructions in Chapter – 6 for erection of CB. Chapter – 7 for erection of isolators and Chapter – 8 for erection of CTs.5 7. Verification of ratio between primary & secondary windings of the Residual Voltage Transformers / Neutral Current Transformers.Capacitor Banks 101 7.6 Last Updated : 31-1-2008 . Carry out pre – commissioning tests on circuit breaker. 7.4 Checking of polarity between primary & secondary windings of the Residual Voltage Transformers / Neutral Current Transformers.

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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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Rod of the applicable diameter to approximate lengths of 3.1 2.6 metre depth.4.55 meter below the foundation top level. Earth Electrode in Hard Soil: Excavate a pit approximately1 M. electrodes.3 2.4 2. a number of rods are connected together in parallel. excavate a trench which is inclined to the vertical at an angle not more than 30° from the vertical. In all other cases.6 metre depth.00 metres plus 0.2 2.2 2. This will leave 0.106 Construction Manual for Sub Stations 2.1 2. shall be welded together. then 4 nos.25 metres for each length. Augur a hole in the ground to a depth of 3 metres. Earth Electrode in Loose / Sandy Soil: Excavate a pit approximately1 M. For example. S.3. A sketch showing this type of arrangement is given below.2. each of length 1000 mm (3000 ÷ 4 = 750 mm + 250 mm). up to 0. To reduce the depth of excavation and burial of an electrode in case of rocky soil without increasing the resistance. if required.2 2.3 Last Updated : 31-1-2008 . Hence. carry out drilling of the rocky soil for providing the pit for the electrode.4 2.3.4. x 1 M. Place the electrode in the augured hole such that the top of the electrode is 0.3 2. the total length of such electrodes should be equal to 3. The distance between any two electrodes in the example above shall not be less than 2000 mm. x 1 M up to 0.1 2. The resistance in this case is practically proportional to the reciprocal of the number of electrodes used. Backfill the excavation and compact the soil after completion of the work.1 2. 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 0.55 metre below the foundation top level.25 metres of the electrode above the ground for connecting it to the earth mat rods. if the depth of excavation is reduced to 1350 mm (600 mm below ground level + 750 mm electrode depth). Earth Electrode in Rocky Soil: Where rock is encountered at a depth of less than 3600 mm below the foundation level. The distance between two electrodes in such a case shall preferably be not less than twice the length of the electrode.3.3.2 2.2.4.0 PLACING OF EARTH ELECTRODES: (See Annexure – B: (I) EARTH ELECTRODE) Cut M. prepare one end as spike for placing / driving into the ground.25 meters (or more if full length of rod is more) and.

ROD AT EARTH ELECTRODE AND AT MESH CROSSINGS. S. transformer tracks. Where different ground levels are provided in the switchyard. place two pieces of M. Flat of size to be used for earthing risers and length 4 times the diameter of the rods on both sides of this joint. apply bituminous compound to the hot joints. A typical joint is shown in Annexure – B. After welding. the backfilling can also be done with Bentonite. Wherever the earth mat is to cross cable trenches. After welding.S.1 3. Angles from M. Rods in the Earth Mat: Place the rods so that they overlap each other by 4 times their diameter. S. ROD TO M.6. S. A typical joint is shown in Annexure – B. Rods in the Earth Mat: Clamp / hold together the two M.S. 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.3 3. S.80 meter below the foundation top level.4 3.1 3.6.S. Clamp / hold these two lengths of M. S. S. pipes.7. S. Rod.Earthing 107 2. (III): JOINT OF M. (II): JOINT OF M.S. S. and cover the joints with bitumen impregnated tape. First weld these together at the crossing point.9 3. e.6 3. clamp / hold the M. Fabricate four cleats in the shape of M. S.2 Last Updated : 31-1-2008 .7. S. to reduce the resistance to earth.1 3. Fabricate four cleats in the shape of M. 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.. underground service ducts. Thereafter. Backfill the excavation and compact the soil after completion of the work. Rod. Flat of size to be used for earthing risers and of length equal to 10 times the diameter of the M.7 3. or a combination of bentonite and black cotton soil in the ratio of 1:6.7 2. ROD IN EARTH MAT. Flat of size to be used for earthing risers and of length equal to 10 times the diameter of the M. ROD AT EARTH ELECTRODE AND AT MESH CROSSINGS. Rod in the excavated trenches. increase the depth of excavation so that it can be laid at a minimum depth of 300 mm below them.6. Rod of 25 mm diameter. Rods of the electrode and the earth mat together. apply bituminous compound to the hot joints.S.2 3. Straight Joints of M. and weld these pieces on the rods. (II): JOINT OF M. Wherever the earth mat is to cross a road. S. etc. Rods crossing each other. ROD TO M.5 3.6 2. Weld these at all the corners of the joint. 2.5 For connecting the electrode to the earth mat. and cover the joints with bitumen impregnated tape.g.0 3. S. Rods together and weld them on both sides. Lay the M. Angles from M. S.8 2.2 3. Cross Joints of M. 100 mm in case of M. A typical joint is shown in Annexure – B. Weld these at all the corners of the joint.S. First weld these together at the crossing point.3 3. In case of rocky soil. LAYING OF EARTH MAT: Excavate trenches along the specified alignments to a depth of 0.S.. ROD TO M.

In case joints are required to increase the length of the M. apply bituminous compound to the hot joints. The depth shall be 0. S.6 4. and cover the joints with bitumen impregnated tape.4 4. Rod and Earth Electrode: Clamp / hold together the M. drill necessary holes in the riser and fix it with bolts & nuts. Flat below the rod.8 Last Updated : 31-1-2008 . For welded type fitting. For bolted type fitting.2 4.2 3. S. to form a smooth and regular shape to match with the shape / form of the equipment / structures / foundation. weld a length equal to at least twice the width of the M.7. S.S. Flat risers. Flat riser to the rod of the earth mat after fitting / welding it to the equipment / structure / structure peak. Flat should overlap each other by twice the width of the M. S.S. Flat. the two lengths of the M. (VI) JOINT OF M. S. S.8. S.8. Fabricate two cleats in the shape of M. Weld the M.8. clamp / hold them together. S.108 Construction Manual for Sub Stations 3. S. Place the M. Then form a piece of M. Flat of the required length and form / bend it. After placing the M. apply bituminous compound to the hot joints.5 4. S. and weld on both sides of the rod. FLAT TO M. Joint of M. ROD AT EARTH ELECTRODE.S.S.1 4.3 After welding. Backfill the excavation and compact the soil after completion of the work. S. Flat. After welding. Weld these to both the rod and the flat.S.1 3. cut two pieces of M.0 4. Angles from M. Cut M. Alternatively.3 4. Backfill the excavation and compact the soil after completion of the work. FLAT. flats one above the other as above. A typical joint is shown in Annexure – B. PREPARATION AND FITTING OF RISERS: Excavate trench from the equipment / structure foundation to the nearest rod of the earth mat. The fitting to the equipment / structure may be bolted type (earthing terminal / pad of the equipment) or welded type (structure).8 3. FLAT TO M. S. Flat 50 × 6 mm into a stirrup (as shown in the drawing) and place on the joint of the rod and flat. Weld the two sides of the joint as well as the part between the flats on the top surface. (V): JOINT OF M. by heating if required. First weld these together at the crossing point. Weld these at the joint. S. and cover the joints with bitumen impregnated tape. Clamp the earthing risers with the equipment support structures at 1000 mm intervals. ROD TO M.S.80 meter below the foundation top level. A typical joint is shown in Annexure – B.S. Lay the prepared M. Angle 50 x 50 x 6 mm of length equal to the width of the M. Rod. clamp / hold them together to provide good surface contact. Flat and place these on both sides of the joint of the rod and flat. S.7 4. The shape of the risers should be same / similar for the same type of equipment / structure. Rod and the earth electrode. A typical joint is shown in Annexure – B. 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. ROD OF EARTH MAT. After welding. (IV): JOINT OF M. S. S. Flat of size to be used for earthing risers and of length equal to 10 times the diameter of the M. apply bituminous compound to the hot joints and cover the joints with bitumen impregnated tape.3 3. 3.9 4.

4. A drawing showing the typical arrangement for earthing of equipment and its structure is given at Annexure – C.Earthing 109 4.9 Apply red oxide paint and then green enamel paint on the portion of the risers above ground level.10 Last Updated : 31-1-2008 .

110 Construction Manual for Sub Stations ANNEXURE – A Last Updated : 31-1-2008 .

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 .

Cable drums shall be unloaded. place the cable drum on a turn table or jack up the drum on a suitable size of steel shaft.No. small lengths can be unwound from the drum. 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. b) Marshalling Kiosk to Equipment. leaving minimum scrap lengths. 2.3 1. Rolling of drums shall be avoided as far as possible. Type of cable Power cable Control cable Minimum bending radius 12 D 10 D 1. Cables shall not be bent below the minimum permissible limits given below: S. The required lengths of cables are laid between the following equipments: a) C&R Panels in Control Room to Marshalling Kiosk. e) C&R Panel to C&R Panel / other panels in Control room. the number of cables of each size and their lengths shall be assessed. For longer lengths. In the absence of any indication. 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. The drums may be rolled for short distances provided they are rolled slowly and in the direction marked on the drum. 2. d) Equipment to Equipment in switchyard.CHAPTER – 16 CABLE LAYING AND WIRING 1. When the cable is to be taken from drums. 1.4 2. etc.1 GENERAL INSTRUCTIONS: Prior to laying of cables. c) Marshalling Kiosk to Marshalling Kiosk. PAYING OUT OF CABLES: Handle the cable with care to prevent forming of kinks and damage to the insulation of the cable.0 2.3 2. Small cut lengths of cable left after laying long lengths can be used for bus wiring and looping.0 1. The cable laying schedule should then be prepared so that maximum length of the cable in a drum can be utilized. Pulling out of cables from stationary drums shall not be permitted.5 Last Updated : 31-1-2008 .6 Cut lengths of cable which are available as surplus / left over material from other works should preferably be used first.4 1.5 Where ‘D’ is overall diameter of the cable. handled and stored properly.2 2. 1. the drums may be rolled in the same direction as it was rolled during winding.1 2.2 1.

5 4. Cables from CT / CVT / PT.3.1 3. The markers shall project 150 mm above ground and shall be placed at intervals of 30 meters and at every change in direction. identification of initial point and terminating end of equipment / Panel.6.3.. on both sides of a wall / floor crossing & on each duct / conduit entry for identification of the cable. Cable tags shall also be provided inside the switchgear. They shall also be located on both sides of road and drain crossings. 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. the depth shall be increased such that the bottom of the trench is 40cm below them. Cover the cable with bricks and backfill the trench with the excavated sand.6.0 3. The numbering of cables on the tags shall be done as per cable schedule. Location of underground cable joints shall also be indicated with cable marker with an additional inscription "Cable joints".2 3. etc.6 4.3 Last Updated : 31-1-2008 . Cables having D. 3.3. 3.3 4. Power and control cables shall be laid in separate tiers.1 LAYING OF CABLES IN TRENCHES: The cables are placed in the racks in cable trenches.. Rectangular shaped cable tag / marking strip of 1.118 Construction Manual for Sub Stations 3. supply. Cover the bottom of the trench with a layer of sand 25 cm thick. wherever required for cable identification. and a cable number are punched on the cable tag / marking strip.3 3.2 4. At crossings of cable trenches / roads / transformer tracks / pipes / earth mat conductor.C.0 4.4 4.1 4.2 4.0 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. etc.3 4. Marking and Tagging: Directly buried underground cables shall be clearly identified with cable marker made of iron plate. C.6. supply. Lay the cable in the excavated trench. control and relay panels.2 The cables are securely fixed on the racks in the cable trenches. LAYING OF UNDERGROUND POWER CABLES: Excavate trench of 30 cm width and 75 cm depth along the proposed route / alignment. Generally Cable size. The width may be increased in case a number of cables are to be laid. Secure the cables on the supports above ground level. Particular care shall be taken when cables are laid in vertical & inclined cable trenches / galleries / vaults or supports.1 4. Compact the sand by ramming. Marking and Tagging: Provide cable tag / marking strip on all cables at both ends (just before entry into the equipment enclosure).

Cut each wire at the length required for terminating it on the terminal block. 5. therefore. Seal all unused openings for cables in the cable gland plate to prevent entry of vermin and dust. as required) of appropriate size on the wire. etc. strip off the outer and inner insulation sheaths of the cable.3 6. Strip off the insulation of each core of the cable which is to be connected.7 Last Updated : 31-1-2008 . etc.1 5. clamped and tied with nylon strap or PVC perforated strap to keep them in position.3 6. Mark all the spare cores of the cables with tags / ferrules indicating the cable number. shall be neatly bunched.4 6. Cut off the armouring for the stripped off length keeping a small length for fitting in the cable gland. the complete cable number may also be included in the tag / ferrule on each core. Connect the wire to its terminal on the terminal block and tighten to ensure secure and reliable connection. Fit the gland nut and tighten.6 6. wire identification may be difficult.2 5.2 6. For unarmoured cable. WIRE TERMINATION: Identify each cores of the cable either by its physical location / marking / numbering or by testing continuity from both ends. for fixing the cables. Fit the gland nut in the cable.2 5. Mark each core of the cable at both ends with a tag / ferrule as per cable schedule / schematic drawing.2.5 6. strip off the outer and inner insulation sheaths of the cable.Control Cable Laying and Wiring 119 5.1 6. All the wires in the Control & Relay panels. Bend the armouring to fit the gland.2. 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.0 5.0 6. For armoured cables. equipments. In panels in which a large number of cables are terminated. Fit the cable gland on the gland plate of the equipment/ panel. Fix the cable gland on the cable end and then fix the cable gland on the gland plate of the equipment / panel.1 CABLE TERMINATION: Drill the required holes in the gland plates of the panels / equipment. This should be done after proper dressing of the wire in the wiring trough. Crimp the termination end / thimble / lug (pin or ring type.

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

After a discharge.1 volts per cell. The charging current should be limited to a maximum of 20 % of the 10 hour capacity of the Battery Set. Clean the batteries as and when dust accumulates.0) at shorter intervals.2. 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.6 1. or the capacity of the battery charger.0) should be given once in 6 months or when the Open Circuit Voltage (OCV) drops to 2.0 4. fire.25 1. Ambient Temperature in ºC 32 37 42 47 52 1. the batteries must be given a freshening charge (as per para 3. Keep the batteries away from heat sources. the batteries should be recharged immediately.5 1. If the ambient temperature during storage is above 27ºC. 1. The terminal bolt connections should be tightened to a torque as mentioned in the manufacturer’s erection manual. The recommended maximum boost charging voltage is 2.1 Last Updated : 31-1-2008 .0 1.17 BATTERY SETS (VALVE REGULATED LEAD ACID / VRLA) 1.23 V / 2. DO’S & DON’TS: DO’S: a) b) c) d) e) f) g) h) Store the batteries in covered area.2.30 volts per cell.torque the connections once every six months. etc.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. If VRLA batteries are stored for a longer duration at an ambient temperature not exceeding 27ºC. etc.1 1. Re .3 The VRLA batteries should be charged with constant potential chargers. The table below shows the charging interval at the various elevated temperature before which a freshening charge is to be given.4 1.25 V) of VRLA Battery Set should be set as per the manufacturer’s recommendations for maximum service life.2.6. sparks.2 1. Read “Installation and Operating Instruction Manual” prior to installation of the VRLA batteries. then a freshening charge (as per para 3.0 2.2 1.3 Charging Interval (in months) 6. The float voltage (2.5 1.5 3. The electrical contacting surfaces should be free from dust. whichever is earlier.CHAPTER .

4 2.122 Construction Manual for Sub Stations 1. Do not use abrasive brush or steel brush to clean the electrical contacting surfaces. 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.0 3.1 2.6 2. dust storm. Clean terminal surfaces of the cells with clean dry cotton cloth. FRESHENING CHARGE: Give a freshening charge to the Battery Set by gradually increasing the voltage. Do not over tighten the terminal bolts. top cover and instruction labels. 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 .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. 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. No such battery tap is provided in 48 V Battery Set. Lay the cables for connecting the Battery Set to the battery charger. etc. as per manufacturer’s general arrangement drawings. Tighten the terminals and inter cell connectors to a torque as mentioned in the manufacturer’s erection manual.30 volts / cell. Do not mix ordinary conventional lead acid batteries with maintenance free VRLA batteries. Crimp on terminal lugs / thimbles of suitable size at both the ends.5 2. The voltage should not be allowed to exceed 2. 1. on the cells. Make inter cell connections.0 2. rain.6. Do not mix the batteries of different capacities or makes.). if required. ERECTION: Assemble. Fit battery identification label (serial no.1 2.2 2. as supplied. and install the mounting frame / stand in the battery room.7 3. 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).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. Do not allow any metal objects to rest on the battery or fall across the battery terminals. Do not attempt to add water or acid in the batteries. Do not tamper with safety valves.3 2. Erect the modules containing the cells on the mounting frame / stand as per the Manufacturer's manual and erection drawings. front cover. 2. Strip off the insulation of the cable ends and of the wires. Do not install the Battery Set in air tight enclosure.

75 volts or the total battery close circuit voltage reaches 1.Battery Sets (Valve Regulated Lead Acid / VRLA) 123 3. This shall be taken as the period of discharge.30 12 hrs. b) Record the voltmeter and ammeter readings every 5 minutes for the first 15 minutes.98 Volts 1.25 30 hrs. Discharge the Battery Set at its 10 hour rate. and ‘Ct’ is the measured Capacity of the Battery Set at ‘t’ Deg. at a current equal to 10 % of its rated ampere hour capacity till the voltage of any one cell reaches 1.0. C by the formula: C27 = Ct + Ct × 0. C. If this is not achieved.0 and put it in operation in the floating mode as per para 7.23 30 hrs. The temperature of the battery terminal shall be measured as it will be almost the same as the electrolyte.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. 2.2 The duration of the freshening charge and the voltage at which the Battery Set is to be charged.28 12 hrs.30 24 hrs. and thereafter every 15 minutes up to the end voltage. the cell voltages shall not be les than the following values.e. 2. This capacity is corrected to 27 Deg. 4. equalize the voltage of all the cells as given at para 4. a) After six minutes from the start of discharge: b) After six hours of discharge: c) At ten hours of discharge: 1. 4.6 below. C. d) The average temperature of the electrolyte during discharge shall be the average of the temperature readings noted at hourly intervals during discharge. 15 – 32 °C 2.92 Volts 1.25 60 hrs. Either of the two options given in the table below can be adopted. Time Cell Voltage 2. 2.5 If 100% or more capacity is achieved at any time during the above discharge test. are given below.3 During the above discharge test. Below 15 °C 2. with reference to the ambient temperature.4 The capacity of the Battery Set is obtained by multiplying the discharge current in amperes by the time in hours as observed above. 4.43 × ( 27 – t ) . a) Maintain the discharge current within ± 1 percent of the specified rate of discharge. 4. ‘C27’ is the Capacity of the Battery Set at 27 Deg. c) Note the time in hours elapsing between the beginning and end of the discharge..0 4. 100 where ‘t’ is the average ambient temperature of the battery room. Option Temperature Cell Voltage 1.75 Volts 4. Time Above 32 °C 2. Finally charge the Battery Set as per para 5. the matter should be referred to the manufacturer. whichever is earlier.6 Last Updated : 31-1-2008 .75 × n (where n is the number of cells in the Battery Set). i.2 4. 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.

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. 4. the Battery Set should not be accepted and the matter should be referred to the manufacturer. Calculate the capacity as given at para 4. If 100 % capacity of the Battery Set is not achieved even after these five discharges.9 5.0 6.0 Last Updated : 31-1-2008 . Continue the charging till the charging current reduces to a negligible value. DISCHARGING: Discharging of the Battery Set is to be done as per procedure given at paras 4.1. switch off the boost charger.75V. a) b) c) Bypass the cell that has first reached 1.8 Charge and discharge the Battery Set until 100 % capacity is achieved. CHARGING / RECHARGING: Immediately after the discharging is completed.2 8. If the Battery set has achieved 100% capacity. Switch on the float charger after setting its output voltage as per manufacturer’s recommendations. 4.2.75 V until the voltage of all the cells reaches 1.124 Construction Manual for Sub Stations 4. If 100% capacity is achieved within another four discharges. then equalize the voltage of all the cells as given below.7 If 85% or more capacity is achieved during the above discharge test.75 V.2.1 7.3 and take necessary action as required. If this discharge is a capacity test. finally charge the Battery Set and put it in operation in the floating mode.1 6. the Battery Set should be charged by gradually increasing the voltage. Continue discharging the Battery Set at its 10 hour rate.30 volts / cell. Measure the voltages of all the cells of the Battery Set and record for future reference.2 7.1 5. After the Battery Set has been fully charged as per para 5. then charge the Battery set as per para 5.0 5. Keep bypassing the cells that reach 1.2 6.1 and 4. note the time in hours elapsing from the beginning to the end of the discharge. The voltage should not be allowed to exceed 2.

Fix / bolt the DC Panel on the trench provided in the floor of the control room or on the base frame if provided. 4. Connect the other end of the cables in the respective C & R panels. The typical distribution of the MCB’s is as below. First connect the cables to the positive and the negative terminals of the DC Panel.6 2.2 220 kV GSS 220 kV C & R Panels 132 kV C & R Panels 33 kV C & R Panels Annunciation.8 2. 1. Lay the cables from the DC Panel to the battery charger. 11.5 2.CHAPTER . Lay the cable from the LT Panel to the DC Panel for AC supply. Lay the cables from the DC Panel to the respective C & R Panels / equipment. Strip off the insulation of the cable ends and of the wires. 1. Measure insulation resistance of panel wiring with 500 V Megger before connecting any cable.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. 8. Crimp on terminal lugs / thimbles of suitable size at both the ends.2 2. 132 kV side Annunciation.3 2. 5. The DC supply to the panels / schemes is connected as per the DC supply scheme. 33 kV side LT & RTCC Panels PLCC / SLDC Emergency Light Spare At 400 kV sub stations. Connect the cable at both the ends. 132 kV side Annunciation.3 2.0 1. 7. two independent Battery Sets and DC Panels are provided. Connect one end of the individual cables to the terminals in the terminal blocks corresponding to the designated MCB’s in DC Panel. 9.0 2. Then connect the cables to the positive and the negative terminals of the battery charger. Strip off the insulation of the cable ends and of the wires. 6. Strip off the insulation of the cable ends and of the wires.18 DC PANELS 1. ERECTION AND INSTALLATION: Check the DC Panel for any mechanical damage before installation. Crimp on terminal lugs / thimbles of suitable size at both the ends.7 2. Place the DC Panel at its designated location in the control room as per layout. 220 kV side Annunciation.4 2. 10. 2. S.1 2.No. 3.9 Last Updated : 31-1-2008 . 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. 1. Crimp on terminal lugs / thimbles of suitable size at both the ends.

The voltages at “+ve to Earth” and “–ve to Earth” positions of selector switch should be equal. If the “–ve to Earth” voltage is less than the “+ve to Earth” voltage.0 3.7 3. 3. i. and rectification if required. POST – COMMISSIONING TESTS: Switch on the individual MCB’s and check the voltage and polarity of DC supply at the corresponding outgoing terminals. Trace the fault and rectify the earth fault.1 4. The voltmeter should show full DC voltage. If the “+ve to Earth” voltage is less than the “–ve to Earth” voltage. Check the annunciations such as “DC supply fail”.4 3. Switch ON the boost circuit and switch OFF the float circuit in the battery charger. Check the working of the DC earth fault relay. it indicates an earth fault in the DC system connected at this stage. Check the operation of the emergency lighting system.1 3. Keep the voltmeter selector switch in the position “+ve to –ve”. “DC earth fault”.3 4.8 after switching on each MCB. Set it at the minimum setting.2 4. Check the voltages on the voltmeter at the different selector switch positions of “+ve to Earth” and “–ve to Earth”. Check the availability of battery tap voltage. Check functioning of space heater and internal illumination circuits. Carry out checking of DC earth fault.8. Switch off the AC supply to the DC Panel. it indicates an earth fault in the negative circuit. Check that AC supply is available at the designated outgoing terminals for the emergency lighting circuit. it indicates an earth fault in the DC system connected at this stage.5 3. by following the steps given at para 3. Check the voltage and polarity of the DC supply at the terminals of the incoming cable from battery charger. etc.0 4. Identify the polarity (+ve or –ve) which is earthed as given at para 3.126 Construction Manual for Sub Stations 3.7 and para 3.. Check that DC supply is available at these outgoing terminals.3 3. as provided in the DC Panel. Check the voltage on the voltmeter at the selector switch position “+ ve to – ve”. If these are not equal.4 Last Updated : 31-1-2008 . Switch on the AC supply to the DC Panel. If the relay operates. Check earthing of the DC Panel to the earth mat.8 3. per cell voltage multiplied by the tapped cell (48th cell of 110 V DC system or 96th cell of 220 V DC system). it indicates an earth fault in the positive circuit.2 PRE – COMMISSIONING CHECKS: Check tightening of all terminal connections.e. The voltage on the voltmeter should correspond to the tapping voltage.6 3.9 4.

PRE – COMMISSIONING CHECKS: Check tightening of all terminal connections.2 1.3 3. Switch off the Float Charger. Place the Battery Charger at its designated location in the control room as per layout.2 4. Check the annunciations such as “AC supply fail”. Keep the Auto – Manual switch in Manual position.2 4. The output voltage should increase to the set value. Put the switch in the Manual position and lower the voltage.7 4.0 1. Set the output voltage to the required value. Fix / bolt the Battery Charger on the trench provided in the floor of the control room.0 3. Raise the voltage manually to the required output value and check the voltage and polarity on the load and battery terminals.3 1. During battery boost charging and in float operation.4 4.0 2.CHAPTER . ERECTION AND INSTALLATION: Check the Battery Charger for any mechanical damage before installation.1 4. it should be ensured that the rating of the relevant section is not exceeded. “DC earth fault”. Switch on the Boost Charger. Adjust the voltage setting if required.5 4. Calibrate the DC voltmeter. etc. Place the temperature sensor in the battery room and connect it to the Battery Charger. Repeat the above test by increasing the voltage.0 4.4 2. 1. Keep the Boost Charger voltage selecting taps (Coarse and Fine) / voltage setting at the minimum position.9 Last Updated : 31-1-2008 . Keep the Auto – Manual switch in Auto position.1 GENERAL INSTRUCTIONS: Maintain a minimum spacing of 15 cm between the Battery Charger and other panels on both the sides for proper ventilation. The output voltage should decrease to the set value. Check earthing of the Battery Charger to the earth mat. ALWAYS KEEP THE FLOAT CHARGER ON EVEN WHEN BOOST CHARGING THE BATTERY SET IN SERVICE.19 BATTERY CHARGERS 1. The cables to the Battery Set and the DC Panel should not be connected.8 4. Switch on the AC supply and check the voltages on the terminals of the incoming cable.3 4.6 4. Lower the voltage manually to check operation of the control circuit.1 3. “Fuse Failure”.2 2. Put the switch in Auto position. PRE – COMMISSIONING TESTS: Connect only the AC supply cable from the LT Panel. Switch on the Float Charger.1 2. as provided.

the float output voltage and current should automatically decrease. Switch on the Boost Charger. 4.1 5.128 Construction Manual for Sub Stations 4.5 5. Switch off the Float Charger.0 5. The output ammeter will show load current when the output voltage exceeds the Battery voltage. When the load current exceeds the setting of the current limiting circuit. Put the Keyed Push Button (Boost as Float) in the ON position. Switch on the Float Charger.13 5. Raise the voltage. It should also show the Tap voltage in Battery Tap position. Check that the rated voltage is available on the load terminals. Switch off the Boost Charger.12 4. 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. After connecting load to the Battery set. Set the voltage to the rated value. Keep the Boost Charger voltage selecting taps (Coarse and Fine) / voltage setting at the minimum position. Adjust the setting of the output current limiting circuit so that the output current does not exceed the rating of the Float Charger.2 5. Raise the voltage manually. Check that the charge / discharge ammeter also shows current in the charge direction. put the Auto – Manual switch in Manual position and decrease the output voltage. Connect the cables to the Battery Set and the DC Panel. Switch off the Boost Charger. The float output current will start increasing. If this does not happen.4 5. Return the voltage selecting taps (Coarse and Fine) / voltage setting to the minimum position. The float output ammeter will show load current when the output voltage exceeds the Battery voltage.3 5. Raise the voltage to the maximum output value and check the voltage on the battery terminals. Put the Float Charger Auto – Manual switch in Auto Position. Reduce the voltage. The float output ammeter will show load current when the float output voltage exceeds the Battery voltage.11 4. POST – COMMISSIONING CHECKS: The voltmeter should show the Battery voltage in the Battery position. Check that the charge / discharge ammeter shows current in the charge direction.6 Last Updated : 31-1-2008 .10 Check the voltage and polarity on the battery terminals. Keep the Float Charger Auto – Manual switch in Manual position. The charge / discharge ammeter on the Battery Charger should show the current on the discharge side.

3 2.2 Last Updated : 31-1-2008 .1 2. protection schemes. as provided. In the case of Duplex type of panels. ICT’s. ERECTION AND INSTALLATION: Place the panels at their designated locations on the trenches in the Control Room as per layout.0 4. Level the panels and check their verticality. PRE – COMMISSIONING TESTS: Arrange for testing. integrating meters. transducers. in the Control Room. 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. Bus Bar Protection schemes.3 3. integrating meters. indicating meters.20 CONTROL & RELAY PANELS 1. of individual relays.4 2. indicating meters. Arrange for testing and verification.1 4. Connect the Bus wiring / interconnecting wiring between the control & relay panels of the Duplex type.5 2. 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. Disturbance Recorders. these shall be bolted together. ICT’s. Also fit the covers for the corridor portion. There shall be no gap between panels which are placed adjacent to each other. for their 1.0 1. Check that there is no physical damage to the relays and other equipment installed in the C&R Panel.2 3.1 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). Event Loggers. by the Protection wing. S.4 4. Check the polarity of DC supply in the Control & Relay Panel.3 2.2 1. for conformity of their characteristics to the specifications and to the technical information / details / particulars intimated by the manufacturer. etc. as well as special schemes / equipment for 400 kV GSS should be tested / got tested as per their schematic diagrams. Check earthing of the panels & its connection to the earth mat. etc. protection schemes.0 3. of individual relays. LBB Protection schemes. Angle fitted on the top of the walls of the trench or on the base frame.6 3. Fix or bolt the panels (as per requirement of installation of the panels) on the channel / M. by the Protection wing. transducers. connect the control panel to the relay panel across the corridor using the fittings provided with the panels.2 2.1 3. etc. PRE – COMMISSIONING CHECKS: Check the tightness of all terminal connections.CHAPTER . Check the availability of DC supply and AC supply in the Control & Relay Panels.0 2.

4 Test the protection scheme logics for alarm and trip as per approved schematic drawings. Trip protections such as differential. provided in C&R Panels for transformers 4.5 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. Operation of 1. over current. provided in C&R Panels for feeders & other circuits 5. etc. The protection scheme logics and annunciation schemes are generally checked as below.3 4.130 Construction Manual for Sub Stations performance at the applied voltage / current / operating supply and at the settings selected for their service conditions.8 4. etc. provided on transformers 2. The actual tripping of the circuit breakers should be checked only two or three times with the operation of the Master Trip Relay. earth fault. 4. etc. No. earth fault. etc. and making necessary changes in the settings if and as required. low oil level. 4. 4. as provided in the scheme logic.7 4. protection schemes. of stability of protection schemes such as differential protection scheme for transformers. provided on transformers 3. Trip protections such as Buchholz.2 4. Test the annunciation scheme by actuating individual alarms from the initiating equipment such as relays. transformer.6 Arrange for testing. etc. by the Protection wing.8. Give the carrier send signal from the Relay Panel and verify that the carrier signal is received back in the Relay Panel.1 4.3 Last Updated : 31-1-2008 . Test the tripping & inter-tripping of associated circuit breakers on the operation of relays / protection schemes. OSR. Alarm protections such as high oil & winding temperature. Alarms provided in circuit breakers 6.8. Put the PLCC equipment on local loop test. etc. Trip protections such as distance. Put the PLCC equipment in the normal mode at both the ends. over current.8. Lockouts provided in circuit breakers Check Points Alarm Operation Tripping of annunciation of Master HV & LV Trip Relay CB’s Alarm annunciation 4. etc. Testing of Carrier Trip Commands: These tests should be carried out for all the codes. circuit breakers. and their closing interlocks.

Control and Relay Panels 131 4. Carrier Received. of directional feature of over current.10 4. 4. Verify the operation of equipments from the control switches / push buttons provided for them. Test the annunciations by actuating individual alarms such as Carrier Fail. 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.0 5.6 4.12 4.8. Verify the interlocks for operation of isolators.7 4. by the Protection wing.11 4. Test the functioning of space heaters and sockets.3 5. Arrange for checking.1 5. etc.8. protection schemes. Arrange for checking and verification. Verify that the carrier signal is received in the corresponding Relay Panel at this end.4 Last Updated : 31-1-2008 . etc. POST – COMMISSIONING CHECKS: Check phase sequence of the VT supply in the Control & Relay panels. meters. and check their readings in the relays. Ask the Engineer at the other end to send the carrier send signal from the Relay Panel at his end.5 4.9 4. by the Protection wing. Measure the voltage & current in the relevant circuits.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. of stability of transformer differential protection on load. earth fault. from the PLCC equipment.8. etc. and distance protection schemes.8.2 5. as applicable. Test the internal illumination system including operation of the door switches.13 5.

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

8. 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. First connect the cable to the LT Panel.7 2. Fix / bolt the LT Panel on the trench provided in the floor of the control room. 3.2 At 400 kV sub stations. 10. 2. 2. The AC supply to the panels / equipments / kiosks is connected as per the AC supply scheme. ERECTION AND INSTALLATION: Check the LT Panel for any mechanical damage before installation.8 Last Updated : 31-1-2008 . 9. 4. 14.4 2. Strip off the insulation of the power cable ends and of the wires. 5. Then connect the cables to the LT terminals of the station transformer. etc. Lay the cables from the LT Panel to the respective bay marshalling kiosks / C & R panels / transformer. 1.0 1. Crimp on aluminium terminal lugs / thimbles of suitable size at both the ends. 7. 12. 6.No.CHAPTER . 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. Crimp on terminal lugs / thimbles of suitable size at both the ends.6 2.1 2. Place the LT Panel at its designated location in the control room as per layout.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).21 LT PANELS 1. The typical distribution of the SFU’s is as below. S. 11.2 2. Strip off the insulation of the cable ends and of the wires. Lay the power cable from the station transformer to the LT Panel. two independent Station Transformers and LT Panels are provided.0 2.5 2.3 2. 13.

3.5 3. 2.3.2 3.4 3. LT Circuit Breaker: ENSURE THAT THE CLOSING SPRING IS FULLY DISCHARGED.10 3.3.7 3.3. Check tripping of LT CB from Protection Trip. Crimp on terminal lugs / thimbles of suitable size at both the ends. If it is not fully discharged.9 3.3.1 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.8 3. Lay the cable from the DC Panel to the LT Panel for DC supply. Connect the cable at both the ends. mechanical latches and stopper(s) as provided. The breaker should close and then trip and should not close again. Check operation of the outgoing Switch Fuse Units and its locking mechanism. Carry out slow mechanical operation (closing and tripping) of Circuit Breaker as per procedure prescribed by the manufacturer. Check the annunciations for protection trip. Strip off the insulation of the cable ends and of the wires. Check operation of anti – pumping / anti – hunting relay by giving continuous closing and tripping signals simultaneously.3. CLOSED. Lubricate all the moving parts and the pins in the operating mechanism.3. Check operation of the LT Circuit Breaker electrically.2 3. Charge the spring electrically and verify the operation of the limit switch. PRE – COMMISSIONING CHECKS: Check tightening of all terminal connections.11 3.5 4.9 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. Last Updated : 31-1-2008 .3. Check lamp indications of the LT CB for CB OPEN.3.3 3. then discharge the spring as per instructions given in the manufacturer’s manual.1 3. Connect the other end of the cables in the respective equipment.3. AUTO TRIP and SPRING CHARGED conditions. Manually charge the closing spring and check electrical limit switch.10 3.1 3. Check rating of fuses in switch fuse units (SFU’s).134 Construction Manual for Sub Stations 2. etc.0 4. Adjust the setting of the limit switch if required.4 3. as provided.3.6 3.0 3. Take all the precautions mentioned in the manufacturer’s manual. Close and trip the LT CB manually.3 3. Check earthing of the LT Panel to the earth mat.

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. Switch on the individual switch fuse units and check the voltage of AC supply at the corresponding outgoing terminals. Close the doors / openings provided in the LT Panel. The voltmeter should show voltage corresponding to the voltage of incoming supply. Check the voltage on the voltmeter at the different positions “R – Y”.0 5. Energy Meter.4 5.1 5. “Y – B” and “B – R”.3 5. testing of LT Current Transformer.2 5.2 Arrange for checking of operation of Over Current and Earth fault relays & their settings. Check functioning of space heater and internal illumination circuits.5 Last Updated : 31-1-2008 .LT Panels 135 4. by the Protection Wing. 5. etc.

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

Earth the Carrier Set and the structure / frame. if received separately.8 2.4 DO NOT alter user settings unless it is absolutely necessary. DO NOT insert or eject the modules from their location in the shelf when the power supply is ON. 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.5 2. Then grout the structure / frame.0 2.4 2. DO’S AND DON’TS: i) ii) iii) iv) v) vi) vii) 1. Fit the co – axial cable on the Carrier Set and LMDU.22 PLCC CARRIER SETS 1. Level the Carrier Sets and fix them on the structure / frame. Check the Carrier sets for any mechanical damage during transportation. DO ensure that all connections are firmly tight. 1. Erect the Carrier sets at their locations on the fabricated structures / frames. The structure/ frame should have a height of at least 150 mm from floor level to facilitate cable entry in to the panel.5 2.0 1. Prepare the ends of the co – axial cable and fix the connectors at the ends. DO keep hand set and measuring leads inside the PLCC terminal.7 2.3 2. Lay the co – axial cable from LMDU to the Carrier Set.2 2.9 2. 1. DO take all the antistatic precautions.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.CHAPTER .3 The erection and installation work should be carried out as per instructions/ procedure given in the Manufacturer’s Installation and Commissioning Manual. Clean the interior of the rack of the Carrier sets with vacuum cleaner. Insert the modules. The work should be done under the supervision of the Work – In – charge / Manufacturer’s Engineer and as per instructions given by him / them. DO ground the terminal chassis properly. Maintain a minimum spacing of 30 mm between two carrier sets on both the sides for proper ventilation. in their designated locations in the Carrier Terminal as per erection manual.10 Last Updated : 31-1-2008 . ERECTION AND INSTALLATION: Fabricate the structure / frame as per the fixing dimensions of the Carrier sets.6 2. Do not disturb the factory settings of the equipment. DO keep the equipments in dust free environment.1 2.2 1.

a) b) c) d) e) Signaling operation by extending ground.3 3.2 4.9 3.8 3.138 Construction Manual for Sub Stations 3. etc. Check the internal illumination system.5 Verify the following.4 4. Pilot levels at HF co-axial. Switch on the MCB. Tx & Rx frequencies. Check that all the inter – connectors are fitted and properly inserted. measurement and adjustment of frequency and levels at both ends (transmitted / received) as per commissioning manual of the manufacturer.7 3.4 3. Output of power amplifier at 125 / 75 Ohm termination. Switch on the Power Supply Unit.10 4. AGC level. Last Updated : 31-1-2008 .0 Ohm for safety. Ensure that the earthing of the HF terminal of the CVT and the LMU / LMDU have been opened. Any other setting / test as prescribed by the manufacturer. Carry out setting. Check the functioning of power sockets. The earthing connection should have resistance of less than 1.1 PRE – COMMISSIONING CHECKS: Measure the resistance of the earthing connections of the Carrier Sets to the earth mat.6 3. IF and RF levels. Check that all the modules are fitted in their correct locations. 3.2 3. Measure output voltage at the test points.3 4. Communication with the remote end operator over service telephone.0 3.0 4. PRE – COMMISSIONING TESTS: Connect 48V from DC power source to Carrier set and check the polarity of DC voltage at the terminals. All the alarms in all the units.5 3. 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. Any other setting / test as prescribed by the manufacturer. 2W & 4W AF levels. Loop back status (local loop and remote loop). a) b) c) d) e) f) g) h) Test tone of 800 Hz / 1000 Hz at the test point. Check the tightness of all terminal connections. Ensure that the exhaust fan is working. Visually check the cards for any dry solder in the circuit.1 4.

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

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

PRE .6 3.1 2.1 1. Check that all the modules are fitted in their correct locations. 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. Check Tx and Rx Trip commands for their proper operation.0 3.5 ERECTION AND INSTALLATION: Check the Carrier Protection Coupler for any mechanical damage before installation.0 2.23 CARRIER PROTECTION COUPLERS 1.2 3. 3. This should be done for all the codes. Fit the Protection Coupler in the PLCC terminal if received separately.2 2. Clean the Protection Coupler with vacuum cleaner. 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. Test the equipment on local loop test.4 3. from the Protection Coupler. PRE – COMMISSIONING TESTS: Check the DC voltage and its polarity in the Protection Coupler.4 3.COMMISSIONING CHECKS: Visual check for any dry solder in the circuit boards. Carrier Received.3 3.7 3. Check tightness of all terminal connections.1 3. etc. Put the equipment on local loop test. Configure the equipment as per programming table. Make connections from the respective Relay Panels to the MDF (main distribution frame) of the equipment as per scheme. Put the equipment in the normal mode at both ends.8 Last Updated : 31-1-2008 . Check that all the inter – connectors are fitted and properly inserted.3 2.CHAPTER .2 1.0 1.3 2.

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

5 1.4 1. Measure various output voltage at the specified test points. Switch on the power supply unit. Grout the structure / frame in the PLCC Room near the cable trenches.6 2. Earth the Exchange and the structure / frame.8 3. 1.4 2. The structure / frame should have a height of at least 75 cm above floor level. Again check the various voltages at test points. Switch off the power supply unit and plug in all the cards in to their respective slots. 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. Plug in the power supply module in its respective slot.2 3.0 1. PRE – COMMISSIONING CHECKS: Connect 48 V DC Supply to the exchange and ensure correct polarity. PRE – COMMISSIONING TESTS: Connect the local telephone lines to MDF of the Exchange.7 2.0 3. Dial up the local as well as the remote end subscribers and verify the satisfactory operation of the Exchange.1 3.CHAPTER .1 2. Clean the interior of the PLCC Exchange panel with vacuum cleaner.2 2.5 2.2 1.1 ERECTION AND INSTALLATION: Fabricate the structure / frame as per the dimensions of the PLCC Exchange.3 1.0 2. The system should work normally. Configure the exchange / local numbers / Tie line numbers as per the procedure given in the instruction manual of the manufacturer.3 2. Verify the alarms provided in the Exchange.6 2.3 3. Place the Exchange on the structure / frame and fix it after levelling.24 PLCC EXCHANGE 1.4 Last Updated : 31-1-2008 . Switch on the power supply unit module. Check the PLCC Exchange panel for any mechanical damage before installation. Wire the trunk lines (Tie lines) from the PLCC carrier set to MDF of the exchange.

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

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

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

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