Maintenenace Manual 23.01.17

Draft Manual for Maintenance of
Distribution network, under DHBVN

Contents
PREFACE ............................................................................................................................................ 8
DHBVN AT A GLANCE .................................................................................................................. 10
MAINTENANCE MANAGEMENT ................................................................................................ 13
VARIOUS TYPES OF MAINTENANCE STRATEGIES ............................................................... 14
Reactive Maintenance .................................................................................................................... 14
Preventive Maintenance ................................................................................................................. 17
Predictive Maintenance .................................................................................................................. 19
Reliability Centered Maintenance .................................................................................................. 20
MAINTENANCE PROCEDURES ................................................................................................... 21
INTRODUCTION .......................................................................................................................... 21
SLD OF 33/11KV SUBSTATION ................................................................................................ 21
MAJOR EQUIPMENTS INSTALLED AT 33/11 KV SUBSTATION ........................................ 22
1. POWER TRANSFORMERS ................................................................................................. 22
2. CIRCUIT BREAKERS: ...................................................................................................... 40
3. CURRENT TRANSFORMERS:............................................................................................ 44
4. POTENTIAL TRANSFORMERS ......................................................................................... 51
5. LIGHTNING (SURGE) ARRESTERS: ................................................................................. 53
6. ISOLATORS & EARTH SWITCHES ................................................................................... 56
7. BATTERY AND BATTERY CHARGERS: ......................................................................... 57
8. 11 KV VCB CONTROL AND RELAY PANELS ............................................................. 59
9. 33 KV CONTROL & RELAY PANELS ............................................................................ 60
10. 33 KV OUT DOOR BUS .................................................................................................... 61
11. 11 KV INDOOR BUS ......................................................................................................... 61
12. APFC PANELS ( AUTOMATIC POWER FACTOR CONTROLLERS) ......................... 61
13. ACDB (AC-DISTRIBUTION BOARD):- .......................................................................... 62
EARTHING SYSTEM AT SUBSTATION .................................................................................. 62
33 KV Transmission lines .................................................................................................................. 66
ITEMS USED IN 33 KV LINES ................................................................................................... 66
TYPE OF PROTECTION USE AT 33 KV LINES ....................................................................... 67
MAINTENANCE OF 33 KV LINES ............................................................................................ 68
Condition Monitoring Procedures .................................................................................................. 68
BEST PRACTICES FOR PERSONNEL SAFETY....................................................................... 69
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MINIMUM CLEARANCE (IN M) BETWEEN LINES WHEN CROSSING EACH OTHER ... 69
GUARDING SYSTEM .................................................................................................................. 70
1. P.V.C. Guarding: ................................................................................................................. 71
2. Lecing guarding. .................................................................................................................. 72
AT 11 KV LEVEL ............................................................................................................................. 74
DISTRIBUTION TRANSFORMER ............................................................................................. 74
Introduction ................................................................................................................................ 74
Scope: ......................................................................................................................................... 74
Prerequisites: .............................................................................................................................. 74
Checks & Directives: .................................................................................................................. 74
Authorization .............................................................................................................................. 77
Implementation ........................................................................................................................... 78
Review: ....................................................................................................................................... 78
RING MAIN UNIT (RMU) ........................................................................................................... 79
Introduction: ............................................................................................................................... 79
Scope: ......................................................................................................................................... 79
Prerequisites: .............................................................................................................................. 79
Directives & Checks: .................................................................................................................. 79
Tests: ........................................................................................................................................... 81
Maintenance Activity: ................................................................................................................ 82
Authorization .............................................................................................................................. 83
Implementation ........................................................................................................................... 83
Review: ....................................................................................................................................... 83
UNDERGROUND CABLES ......................................................................................................... 84
Introduction ................................................................................................................................ 84
Scope .......................................................................................................................................... 84
Prerequisites................................................................................................................................ 84
Directives & Checks ................................................................................................................... 85
Minimum permissible Bending radius (Table1) ......................................................................... 86
Depth of the cable (Table-3) ....................................................................................................... 87
Current Rating (Table4)- 11 KV XLPE UG Cable .................................................................... 87
Authorization .............................................................................................................................. 88
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Implementation ........................................................................................................................... 88
Review: ....................................................................................................................................... 88
HT OVERHEAD LINES ............................................................................................................... 89
Introduction: ............................................................................................................................... 89
Scope: ......................................................................................................................................... 89
Prerequisites: .............................................................................................................................. 89
Properly Grounding means ......................................................................................................... 89
Clearance .................................................................................................................................... 90
Current carrying capacity of conductor ...................................................................................... 90
Checks & Directives: For 11 KV O/H Feeders ......................................................................... 91
Tests ............................................................................................................................................ 92
Maintenance Activity: ................................................................................................................ 94
Authorization .............................................................................................................................. 95
Implementation ........................................................................................................................... 95
Review: ....................................................................................................................................... 95
Components of an Overhead 11 KV (H.T.) Line of O/H Lines ..................................................... 96
HT AERIAL BUNCHED CABLE .............................................................................................. 101
Introduction .............................................................................................................................. 101
Scope ........................................................................................................................................ 101
Prerequisites.............................................................................................................................. 101
Laying of AB Cables ................................................................................................................ 102
Characteristics of HT ABC....................................................................................................... 102
Symptoms prior to failure ......................................................................................................... 102
Reason of Failure: ..................................................................................................................... 103
Correctives Measures for Installation snags: ............................................................................ 104
Typical Failure of HT AB cable ............................................................................................... 107
Condition Monitoring of Aerial Bunched Cables: ................................................................... 108
Directives & Checks ................................................................................................................. 109
Minimum permissible Bending radius ..................................................................................... 111
Testing of AB cables: ............................................................................................................... 111
Current Rating .......................................................................................................................... 111
Authorization ............................................................................................................................ 112
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Implementation ......................................................................................................................... 112
Review: ..................................................................................................................................... 112
Cable jointing Process .................................................................................................................. 113
Power cables ............................................................................................................................. 113
Functions of Each Component ................................................................................................. 114
Cable Screen – Theory ............................................................................................................. 114
Role of Earthing in Power Distribution ....................................................................................... 118
Introduction .............................................................................................................................. 118
Earthing In Electrical System ................................................................................................... 118
Reason for Poor Earthing Practices: ......................................................................................... 118
Why Earthing Important? ......................................................................................................... 119
Attributes Of Good Earth Connection ...................................................................................... 119
Statutory Requirement of Earthing - IE RULE 1956 ............................................................... 119
Vulnerable Points to Be Earthed .............................................................................................. 120
Terminology ............................................................................................................................. 120
Types of Earth Electrodes......................................................................................................... 121
Types of Earthing ..................................................................................................................... 124
Selection of Earthing System ................................................................................................... 124
Factors Affecting Earth Resistance .......................................................................................... 124
Earth conductor......................................................................................................................... 125
Comparison of conducting materials ........................................................................................ 126
Earthing arrangement for pole mounted sub-station on DP: .................................................... 126
Limits of Earthing Resistance................................................................................................... 128
Range of tolerable current ........................................................................................................ 128
FUSES .......................................................................................................................................... 129
Introduction .............................................................................................................................. 129
Description................................................................................................................................ 129
Fusing factor ............................................................................................................................. 129
Principle of operation ............................................................................................................... 129
Selection of fuse wire ............................................................................................................... 130
Melting points of various metals .............................................................................................. 130
Current Rating of Fuse wire- .................................................................................................... 131
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Autorecloser and Sectionalisers ................................................................................................... 133
Introduction: ............................................................................................................................. 133
Autorecloser: ............................................................................................................................ 133
Sectionaliser: ............................................................................................................................ 133
Scope: ....................................................................................................................................... 133
Prerequisites: ............................................................................................................................ 134
Directives, Checks and Tests: ................................................................................................... 134
Tests: ......................................................................................................................................... 136
Maintenance Activity and check lists: ...................................................................................... 136
Planned Maintenance Activity and check list: ......................................................................... 137
Authorization ............................................................................................................................ 139
Implementation ......................................................................................................................... 139
Review: ..................................................................................................................................... 140
AT LT Voltage Level....................................................................................................................... 141
LT ACB ........................................................................................................................................ 141
Introduction .............................................................................................................................. 141
Receiving and Handling ........................................................................................................... 142
Storing ...................................................................................................................................... 142
Transportation and Installation at site ...................................................................................... 143
Operation .................................................................................................................................. 143
Maintenance and overhauling ................................................................................................... 144
LT UNDERGROUND CABLES ................................................................................................. 146
Introduction .............................................................................................................................. 146
Scope: ....................................................................................................................................... 146
Prerequisites: ............................................................................................................................ 146
Depth of the cable ..................................................................................................................... 147
LT Cables Current Rating......................................................................................................... 148
Authorization ............................................................................................................................ 148
Implementation ......................................................................................................................... 148
Review ...................................................................................................................................... 148
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LT OVERHEAD LINES .............................................................................................................. 149
Introduction .............................................................................................................................. 149
Scope ........................................................................................................................................ 149
Prerequisites: ............................................................................................................................ 149
Current carrying capacity of conductor .................................................................................... 150
Checks & Directives: LV O/H Feeders ................................................................................... 150
Tests .......................................................................................................................................... 154
Maintenance Activity ............................................................................................................... 154
LT ARIAL BUNCHED CABLE (ABC) ..................................................................................... 157
Introduction .............................................................................................................................. 157
Scope ........................................................................................................................................ 157
Prerequisites.............................................................................................................................. 157
Laying of AB Cables ................................................................................................................ 157
Testing of AB cables ................................................................................................................ 159
Current Rating .......................................................................................................................... 160
Authorization ............................................................................................................................ 160
Implementation ......................................................................................................................... 160
Review ...................................................................................................................................... 160
LT METERING & SERVICE CABLE ....................................................................................... 161
Quality Control Checks on Meters and Metering System: ....................................................... 161
LT FEEDER PILLAR .................................................................................................................. 163
Introduction .............................................................................................................................. 163
Precaution ................................................................................................................................. 163
Check List ................................................................................................................................. 164
LT FUSE BOARD ....................................................................................................................... 165
Introduction .............................................................................................................................. 165
Detail of Materials used in above Fuse Board .......................................................................... 165
Melting points of various metals .............................................................................................. 166
Current Rating of Fuse wire ..................................................................................................... 166
DT wise Connecting cable Rating ............................................................................................ 168
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Check List ................................................................................................................................. 168
RECOMMENDATIONS ................................................................................................................. 169
Diagnosis of LD System andRemedial Measures for attending / minimizing Faults ...................... 170
Various Faults / Point of concern with Probable Causes and Remedial Actions ......................... 171
Distribution Transformers ................................................................................................................ 175
Probable Causes of DT failure and Measures .............................................................................. 176
Distribution transformer failure analysis & corrective actions. ................................................... 180
Power Transformers ......................................................................................................................... 205
Probable Causes of Power Transformers failure and Measures ................................................... 206
Best practices at substation level maintenance ............................................................................ 211
DO’s & DON’T’s for Power Transformers ................................................................................. 214
Battery Bank .................................................................................................................................... 218
Probable Causes of DC failure and Measures .............................................................................. 219
Basic defects observed at battery bank ..................................................................................... 219
Over View of Distribution Lines ..................................................................................................... 221
Probable Causes of Underground Cables failure and Measures .................................................. 222
TYPES OF UNDERGROUND CABLE FAULTS ..................................................................... 224
ROOT CAUSE OF FAILURE ..................................................................................................... 225
Overhead Circuits (O/H Lines) ........................................................................................................ 243
Probable Causes of Overhead Lines Faults and Measures ........................................................... 244
Fault in Overhead Lines ............................................................................................................... 246
Corrective & Preventive Action ................................................................................................... 256
Aerial Bunched Cable (ABC) .......................................................................................................... 267
Faulty Joints of Aerial Bunched Cables ....................................................................................... 268
Best Practices for Jointing of AB Cables ..................................................................................... 273
General Tools for Installation of AB Cable ................................................................................. 276
CHECK LISTS/ ANNEXURES ...................................................................................................... 277
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PREFACE
In the modern era and under the pressure of rapid development around the regions, electric utilities
are challenged with a numerous of challenges that include aging infrastructure, enhanced
expectation of reliability, reduced cost, and coping effectively with uncertainties and changing
regulation requirements.
Indeed, for Power Distribution Utility distribution Network represent a complex and critical
physical assets that requires a careful evaluation of their maintenance practices aiming at more cost-
effective tasks.
The first concern of the electric power distribution company is the optimization of the distribution
network maintenance scheduling, to minimize system operating costs and ensure that the system is
running most economically& safely. There is significant pressure on power providers for greater
system reliability and improvement of customer satisfaction, while similar emphasis is placed on
cost reduction. These cost reductions focus on reducing operating and maintenance expenses, and
minimizing investments in new plants and equipment. The optimization of maintenance is one
possible technique to reduce maintenance costs while improving reliability and utilities need to
implement new strategies for more effective maintenance techniques and Asset Management (AM)
methods programs to manage inspections and maintenance activities in order to control HV/MV
substation equipment conditions. However, development of strategies to make sound decisions in
order to effectively improve equipment and system reliability while meeting constraints such as a
maintenance budget is a challenge
Modernizing assets is capital intensive, and for the utilities / industry, regulatory and compliance
requirements many times hinder asset replacement. The business case for early replacement of an
asset with a more modern intelligent version has to be weighed against keeping the old model for a
longer period. This is where the utilities required a more robust maintenance system. Utilities have
progressed from primarily a reactive, break and fix “repair” approach towards a preventive
maintenance approach. Considering the broad array of assets for which utilities are responsible —
Transformers, Circuit Breakers, Ring main units (RMU) and cables — and the risks associated with
asset failure, a reliable maintenance strategy is a priority for the distribution industry. This is the
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primary reason why maintenance systems being developed in power utilities. Some advantages of
maintenance system are more direct, such as getting ahead of equipment failures to hopefully avoid
major breakdowns or outages, or avoiding replacing perfectly good parts when not actually
required. Other benefits come from having a greater understanding of what components are
deployed in the field. The future of asset maintenance is prescriptive, and each step towards this
goal helps companies reduce costs, ensure equipment availability and up-time, increase service
reliability, and most important improve safety.
There is a huge need for the utilities maintenance programs to include rigorous inspection and
assessment procedures – ones that are sometimes quickly being adopted by Predictive asset
maintenance and sometimes by Reliability Centered Maintenance - unfortunately there is a wide
perception exists that offers reaction to failure rather than preventative maintenance. Well-
developed and well-managed maintenance system, designed to prolong and preserve asset lifetime,
are cost-effective if utilities are aware of the current condition of their assets. The right data on
assets is key in deciding where to spend the time & money. An asset life can be extended 10 - 20
years at a cost much lower than the cost of recovering from a critical failure or a new asset.
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DHBVN AT A GLANCE
Name of Zone Name of District

(OP) Circle Covered
Faridabad Faridabad
Palwal
Palwal
Mewat
Delhi Zone
Gurgaon Gurgaon
Narnaul Mohindergarh
Rewari Rewari
Bhiwani Bhiwani
Hisar
Hisar
Hisar Zone Fatehabad
Sirsa Sirsa
Jind Jind
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Parameter No. Unit
Districts 11 Nos.
Towns 55 Nos.
Villages 3652 Nos.
Connections-all categories 3017821 Nos.
Distribution transformers installed 243122 Nos.
Capacity of Distribution transformers 11994 MVA
Connected Load 13754 MW
33 kV Substations 273 Nos.
33 KV Line 3261 kM
HT Line (11KV) 70593 kM
LT Line 63842 kM
11 KV O/G Feeders 4374 Nos.
LT / HT Ratio (63842KM / 73854 0.86
KM)
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MAINTENANCE MANAGEMENT
Maintenance Management characterizes the process of leading and directing all or part of an
organization, often a business one, through the deployment and manipulation of resources (i.e.
human, financial, material, intellectual or intangible).
One can also think of management functionally as the action of measuring a quantity on a regular
basis and adjusting an initial plan and the actions taken to reach one's intended goal.
 This applies even in situations where planning does not take place. Situational management
may precede and subsume purposive management.
 Maintenance management will therefore characterize the process of leading and directing the
maintenance organization.
 Maintenance is defined as the combination of all technical, administrative and managerial

actions during the life cycle of an item intended to retain it in, or restore it to, a state in which it
can perform the required function (function or a combination of functions of an item which are
considered necessary to provide a given service).
 We can define maintenance management as follows: All the activities of the management that
determine the maintenance.
 Objectives or priorities (defined as targets assigned and accepted by the management and
maintenance department), strategies (defined as a management method in order to achieve
maintenance objectives), and responsibilities and implement them by means such as
maintenance planning, maintenance control and supervision, and several improving methods,
including economic aspects in the organization.
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VARIOUS TYPES OF
MAINTENANCE STRATEGIES
Based on Requirement, Resources & Priorities of an Organization for maintenance of any Network
/ System, broadly following maintenance Strategies are being followed:
 Reactive Maintenance
 Preventive Maintenance
 Predictive Maintenance
 Reliability Centered Maintenance
Details of these type of maintenance strategies are given below.
Reactive Maintenance
Reactive maintenance (also known as “breakdown maintenance”) is basically the "run it till it
breaks" maintenance mode. No actions or efforts are taken to maintain the equipment, facility, as the
designer originally intended to ensure design life is reached.
In other words Reactive maintenance are repairs that are done when equipment has already broken
down. Reactive maintenance focuses on restoring the equipment to its normal operating condition.
The broken-down equipment is returned to working within service specifications by replacing or
repairing faulty parts and components.
Advantages to reactive maintenance can be viewed as a double-edged sword. If we are dealing with
new equipment, we can expect minimal incidents of failure. If our maintenance program is purely
reactive, we will not expend money on manpower or incur capital cost until something breaks.
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Advantages:
 Low Maintenance Cost
 As no Maintenance is done until the equipment is Fails / broken

down, therefore no Cost required for regular / periodic maintenance.
 Less Manpower / Staff members required
 As no Maintenance is done until the equipment is Fails / Broken

down, therefore no Manpower / Staff required for regular / periodic
maintenance
 No Maintenance Planning needed
 As maintenance is done on equipment only when it fails and fails are

unpredictable therefore No time is spent on maintenance planning.
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Disadvantages:
 Difficult to control budgets
 Increased cost due to unplanned downtime of equipment, unsafe

housing
 As equipment failures can be unpredictable, labor and spare parts
may not be readily available so organizations may end up paying a
premium for emergency parts shipping, travel time and out of hours
support
 Possible secondary equipment, facility, or process damage from
equipment failure.
 Low component life cycle or Shorter life expectancy of assets
 Reactive maintenance does not keep the systems running in optimal

“as new” condition. Over time, systems that have been maintained
deteriorate faster so don’t maximize their initial capital cost
investment.
 Safety issues
 When work is scheduled, technicians have time to review the

standard procedures and safety requirements to complete the job
correctly. Technicians tend to take more risks when maintenance
work is reactive as they are under pressure to get systems running
without delay.
 Time consuming
 Reactive repairs tend to take longer due to a number of factors

including time to diagnose, travel time, time to pull parts from stores
or emergency order, time to pull correct manuals and schematics etc.
 Irregular equipment downtime
 Planned maintenance can be written into the production schedule

whereas unplanned repairs can happen anytime. Also, there is the
uncertainty around the length of delay due to the repair.
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 Inefficient use of resources
 Technicians spend time running around looking for the correct

manuals and schematics, ordering the right parts etc. trying to
diagnose and fix the issue.
 Interferes with planned work
 Emergency repairs are usually prioritized at the expense of planned

work. Planned work may be pushed or cancelled completely. Because
it increases the labor cost, especially if overtime is needed.
 Collateral Damage
 A minor issue could quickly into a major system repair. I personally

had a water leak that spilt onto an electronics cabinet, causing tens of
thousands of money in damaged electronic boards.
 Indirect costs
 Unplanned downtime can lead to late orders if equipment cannot be

returned to production in time. This can damage reputations and
impact revenues.
 Repeat issues
 Reactive maintenance does the bare minimum to get the system up

and running again. If not repaired correctly, the issue could reoccur
and cause more downtime.
Preventive Maintenance
Preventive maintenance can be defined as follows: Actions performed on a time- or machine-run-

based schedule that detect, preclude, or mitigate degradation of a component or system with the aim
of sustaining or extending its useful life through controlling degradation to an acceptable level.
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In other words Preventive maintenance is maintenance that is regularly performed on a piece of
equipment to lessen the likelihood of it failing. Preventative maintenance is performed while the
equipment is still working, so that it does not break down unexpectedly.
Preventative maintenance is planned so that any required resources are available.
The maintenance is scheduled based on a time or usage trigger. A typical example of an asset with a
time based preventative maintenance schedule is an air-conditioner which is serviced every year,
before summer. A typical example of an asset with a usage based preventative maintenance
schedule is a motor-vehicle which might be scheduled for service every 10,000km
Advantages:
 Increased component life cycle.
 Due to Timely & proper Maintenance of Equipment. As Overall Life

Cycle is improved
 Reduced equipment or process failure
 Due to Timely & proper Maintenance of Equipment. As Overall Life

Cycle is improved
 Estimated 12% to 18% cost savings over reactive maintenance program.
 In case of Reactive Maintenance, due to lack of proper maintenance,

fault / Damage of Equipment is more sever however in this case
possibility of Sever Fault / damage is almost negligible there by cost
saving on maintaining / replacing the Equipment.
 Cost effective in many capital intensive processes.

 Flexibility allows for the adjustment of maintenance periodicity.
 Energy savings.
Disadvantages:
 Increased cost due to unplanned downtime of equipment, problems moving

IDP individuals from houses, buildings, facilities, while work is being
completed.
 Increased labor cost, especially if overtime is needed.
 Cost involved with repair or replacement of equipment.
 Possible secondary equipment or process damage from equipment failure.
 Inefficient use of staff resource
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Predictive Maintenance
Predictive maintenance is designed to help determine the condition of in-service equipment in order
to predict when maintenance should be performed. This approach promises cost savings over
routine or time based preventive maintenance, because tasks are performed only when warranted.
Basically, predictive maintenance differs from preventive maintenance by basing maintenance need
on the actual condition of the machine, house, facility, rather than on some pre-set schedule,
preventive maintenance is time-based.
Activities such as changing lubricant are based on time, like calendar time or equipment run time.
For example, most people change the oil in their vehicles- every 3,000 to 5,000 miles
No concern is given to the actual condition and performance capability of the oil. It is changed
because it is time.
This methodology would be analogous to a preventive maintenance task. If, on the other hand, the
operator of the car discounted the vehicle run time and had the oil analyzed at some periodicity to
determine its actual condition and lubrication properties, he/she may be able to extend the oil
change until the vehicle had travelled 10,000 miles. This is the fundamental difference between
predictive maintenance and preventive maintenance, whereby predictive maintenance is used to
define needed maintenance task based on quantified material/equipment condition.
The advantages of predictive maintenance are many. A well-orchestrated predictive maintenance

program will all but eliminate catastrophic equipment failures. We will be able to schedule
maintenance activities to minimize or delete overtime cost. We will be able to minimize inventory
and order parts, as required, well ahead of time to support the downstream maintenance needs.
We can optimize the operation of the equipment, saving energy cost and increasing plant reliability.
Advantages:
 Increased component operational life/availability.

 Allows for pre-emptive corrective actions.
 Decrease in equipment or process downtime.
 Decrease in costs for parts and labor.
 Better product quality.
 Improved worker and environmental safety.
 Improved worker moral.
 Energy savings.
 Estimated 8% to 12% cost savings over preventive maintenance program.
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Disadvantages:
 Increased investment in diagnostic equipment.

 Increased investment in staff training.
 Savings potential not readily seen by management.
Reliability Centered Maintenance
RCM: "a process used to determine the maintenance requirements of any physical asset in its
operating context.
RCM methodology deals with some key issues not dealt with by other maintenance programs.
It recognizes that all equipment in a facility is not of equal importance to either the process or
facility safety. It recognizes that equipment design and operation differs and that different
equipment will have a higher probability to undergo failures from different degradation
mechanisms than others.
Basically, RCM methodology deals with some key issues not dealt with by other maintenance
programs.
Advantages:
 Efficient.
 Increased system reliability.
 Lowered costs due to no unnecessary maintenance.
 Minimized overhauls.
 Reduced sudden equipment failures.
 Maintenance focused on critical components.
 Incorporates root cause analysis.
Disadvantages:
 Significant initial costs for training, and equipment.

 Sometimes savings potential not readily seen by management.
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MAINTENANCE PROCEDURES
INTRODUCTION
Proper maintenance of electrical systems helps in minimizing/preventing unwarranted breakdowns
of Equipment / lines improving the reliability and generating revenue. Periodical or preventive
maintenance is normally followed to keep the equipment continuously in service for desired output.
Condition based maintenance is the most accepted and adopted concept in maintenance now a day’s
which helps in providing advance information about the health of the equipment to take corrective
action in advance.
As the system is growing, it is getting more and more complex. Due to stringent regulations the
utility cannot afford to have breakdowns in the system resulting in interruption of power supply to
the consumer. On the other hand equipment are getting older and are more prone to failure.
Equipment overhaul and major maintenance are also expensive and need to be planned based on the
condition of the equipment rather than on a periodic basis as a routine.
SLD OF 33/11KV SUBSTATION
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MAJOR EQUIPMENTS INSTALLED AT 33/11 KV SUBSTATION
1. POWER TRANSFORMER
2. CIRCUIT BREAKER
3. CURRENT TRANSFORMER
4. POTENTIAL TRANSFORMER
5. LIGHTNING (SURGE) ARRESTERS
6. 33 KV LINE ISOLATORS & EARTH SWITCHES
7. BATTERY BANK & BATTERY CHARGERS
8. 11 KV VCB PANELS
9. 33 KV C&R PANELS
10. 33 KV OUT DOOR BUS
11. 11 KV INDOOR BUS
12. APFC PANELS
13. ACDB ( AC-DISTRIBUTION BOARD)
14. ISOLATORS
15. POWER AND CONTROL CABLE
16. CAPACITOR BANK
1. POWER TRANSFORMERS
A transformer is an electrical device that transfers electrical energy between two or more circuits
through electromagnetic induction. Electromagnetic induction produces an electromotive force
within a conductor which is exposed to time varying magnetic. It constitutes the single most
expensive item in a substation.
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Ratings of Power Transformers
S. Alarm /
No. Tripping
4 5 6.3 8 10 12.5
MVA MVA MVA MVA MVA MVA
1
Differential
relay
     
Pressure
2 Release Valve      
(PRV)
Oil
3 Temperature      
Alarm (OTA)
Oil
Trip (OTT)
Winding
Alarm (WTA)
Winding
Trip (WTA)
Low Oil Level

7 Alarm      
(LOLA)
8
Buchholz
Alarm (BA)
     
9
Buchholz Trip
(BT)
     
10
Over Current
Relay (O/C)      
11
Earth Fault
Relay (E/F)      
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In order to provide long and trouble free service, it is important that a careful and regular
supervision and maintenance of the transformer and its components is carried out. The frequency
and extent of such a supervision and maintenance is dependent on the experience, climatic
conditions, environment, service conditions, loading pattern etc. All work done on transformers
should be recorded in maintenance register / checklist.
POWER TRANSFORMER USED IN DHBVN

CURRENT CURRENT
S. PRIMARY SECONDARY TRANSFORMR TRANSFORMR
RATING
No. CURRENT CURRENT RATIO 33 KV RATIO 11 KV
SIDE SIDE
300-150/5-5-5-5
1 4 MVA 69.98 Amp 209.94 Amp 200-100/1-1-1 Amp
Amp
300-150/5-5-5-5
2 5 MVA 87.48 Amp 262.44 Amp 200-100/1-1-1 Amp
Amp
600-300/5-5-5-5
3 6.3 MVA 110.22 Amp 330.67 Amp 400-200/1-1-1 Amp
Amp
600-300/5-5-5-5
4 8 MVA 139.97 Amp 419.90 Amp 400-200/1-1-1 Amp
Amp
600-300/5-5-5-5
5 10 MVA 174.96 Amp 524.88 Amp 400-200/1-1-1 Amp
Amp
900-450/5-5-5-5
6 12.5 MVA 218.70 Amp 656.10 Amp 400-200/1-1-1 Amp
Amp
Alarms &Trippings provided for Power Transformers being used in Sub Stations under
DHBVN
MAIN PROTECTION OF POWER TRANSFORMER:
This protection shall be a biased current differential protection & relay should include the following
features:
 Vector group compensation.
 CT ratio correction.
 Biased differential protection.
 High-set. Element of suitable setting range
 2nd and 5th Harmonic restrains.
Transformer trouble alarm/ Trip e.g. Buchholz / PRD / Winding Temp / Oil Temp etc. shall be
taken as binary inputs in the differential Relay as a common input indicating “Transformer trouble”
Page 24 of 333
through TMU. However, auxiliary Flag relays/TMU (Transformer monitoring unit) shall be
provided independently for Transformer trouble and trip.
Relay shall be able to display all the Alarms and field status change on the panel at the time of
occurrence and it should be possible to accept the alarms locally from the relay and through the
station controller PC.
BACKUP PROTECTION OF POWER TRANSFORMER:
A non-directional numerical 3 Phase O/C Protection relay with earth fault unit shall be used as a
backup of Transformer
This relays shall have the following function:
 Non directional O/C (each relay shall have one IDMTLand two high
set definite time relay), 50,51N.
 Negative sequence current (unbalance current) 46
 Overload relay (49).
Backup relay shall be used for out zone fault of transformer where 11 KV outgoing & 11 KV
incomer feeders don’t tripped.
Note :- Electrically reset type high speed, heavy duty relay shall be used for tripping on
operation of main or b/u protection relays of the Transformer. The two trip coils where ever
provided shall be provided with independent potential free contacts from different fused DC
supplies. Trip relay shall be supervised.
Page 25 of 333
RESTRICTED EARTH FAULT PROTECTION
Normally, as a cost effective , we are considering Biased differential protection in addition to

transformer auxiliary protection viz. Buchholz’ relay & PRD ; WTI / OTI etc. sufficient to protect
the Transformer against internal faults , but in fact 5 to 10 % of the transformer winding remain
unprotected.
Although Biased differential protection provides excellent protection for phase to phase and most
phase to earth winding faults , this element is less sensitive for single phase to earth faults close to
the earth point in solidly grounded transformers. REF takes advantage of the large current in the
neutral conductor to provide sensitive & fast protection for transformer faults close to earth faults.
Basically, an earth fault relay along with external series resistance and a nonlinear resistor
connected as a high impedance forms HI impedance REF protection.
REF protection is so called unit or restricted one as this defined between the two CT’s.
Hence by connecting an REF relay to CT’s installed in correct locations on the Transformer, one
can use REF protection to compliment differential protection in detecting Transformer earth faults.
Page 26 of 333
General Supervision in 33/11 Power transformer
1. Dirt and Dust: The external transformer surfaces shall be inspected regularly; and when
required cleaned of dust, insects and other air borne dirt etc.
2. Rust and Treatment: A regular inspection is to be done on the external surface of the
transformer tank and radiators.
3. Mechanical Damage: Checks must be carried out for mechanical damage to the fabrications
and associated equipment. Particular attention should be given to vulnerable areas such as
radiators.
4. Check out all Joints for Signs of Leakage: All joints, both welded and gasketted, must be
checked for signs of oil leakage. If there is any doubt of a leak, the area must be cleaned of oil,
using a suitable solvent (methyl alcohol) and sprayed with liquid chalk.
5. Check for Oil Level: All oil levels associated with the equipment including oil conservator
and all oil filled bushings shall be checked. Also the oil in the oil seal should be maintained.
Page 27 of 333
6. After completing all the checks ensure that all materials or tools, used for maintenance work,
have been removed. All clothes and other debris must be disposed of. The transformer
compound should be left in a clean and tidy condition.
7. Silica Gel Breather: In open breathing transformer, the breather plays active role in
maintaining- the transformer dry by admitting dry air when transformer breathes. In
transformers having air cell or diaphragm, the breather ensures dry air inside the air cell or
above the diaphragm. The silica gel inside the breather becomes pink from bottom to top over a
period of time.
General Supervision for conservator:
 Visual Check for Conservator Oil Level

 Leakage Test for Air Cell
 Marshalling kiosks/Cubicles: Checks on physical parameters like condition of
paint, condition of door seal, lights and heaters, cable tightness etc. shall be
done. Operation of alarms and indicating lamps to cover all system functions
shall be ensured.
 Valve Operational Checks: Transformer and associated equipment must be out
of service, isolated and earthed while carrying out these checks. Valve
operational checks are done at the time of erection or at the time of major
overhaul. The checks include checking each valve for free operation, adequate
greasing and for padlocking wherever provided. Each valve shall be returned to
its “in service” operating position (open or closed) and locked after the checks
have been completed.
TESTS OF POWER TRANSFORMERS
Following test should be carried out before the installation of Power transformer
 Polarization index (by Digital Meggar) or Insulation resistance (by Analog meggar)
a) Connect the one lead of meggar at HV side of Transformer and Other one at LV
terminal.
b) Take the IR of 60 Sec and 10 minutes. The ratio of both the results should be greater
than 1 and less than 5.
c) Repeat the same procedure between HV terminal to earth and between LV terminals to
earth.
d) If analog meggar available then just measure the IR of all three condition mentioned
above. It should me 5000MOhm or above for new transformer.
 Ratio Test.
a) Connect the ratio meter if available.
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b) Connect the one terminal of meter at HV side other at LV side to confirm the ratio.
c) If ratio meter is not available then just connect the supply of 440V to HV side and
measure the voltage at LV side with respect to the ratio of PTR (33/11 kv). The
deviation should not be more than 0.5 %.
 Magnetic Balance Test.

a) This test preferably conducted on LV side of Transformer.
b) Connect the supply of 250 volt between (r) phase and neutral (N).
c) Measure the voltage between y-N and b-N. The sum should be equal to supply voltage
d) Repeat the same procedure between y-N and b-N and conform the results.
 Vector group test ( for Dyn11)

a) Short the R phase of HV side with r phase of LV side
b) Supply the voltage (440 V) at HV side.
c) Measure the voltage between R-N, N-Y, B-b, B-y, Y-b and Y-y
d) Condition for confirming vector group of Dyn11 is
1) RN + NY = RY
2) Bb < By
3) Yy = Yb.
MEASUREMENT OF WINDING RESISTANCE

Scope:
 To calculate I2R loss of the winding.

 To ensure proper crimping, brazing and other connections
 To calculate the winding temp. at the end of temperature rise test as a base for assessing
possible damage in the field
Reference:
 IS-2026(Part 1)-1977-Clause 16.2

 IEC-60076(Part 1)-1993-Clause 10.2
 ANSI/IEEE C-57.12.90-1999 Clause 5 BS 171 (Part 1)-1978-Clause 8.2
Equipment required:
Recommended
S.NO Equipment
Range Accuracy
Transformer winding
1 2 m ohm-2000 ohm +/-0.5%
resistance meter
2 Thermometer 0-50 C +/- 1C
Page 29 of 333
Testing Procedure:
For calculation of I2R losses in the winding, it is necessary to measure DC resistance of each
winding. The resistance measurement shall be done by circulating the direct current in the winding
and after it has reached a steady state value. In some cases this may take several minutes depending
upon the winding inductance. The time taken can be a reference for hot resistance measurement at
the time of temperature rise test. Temperature of the winding should be stable and for this session,
the test shall be carried out normally before the load loss.
The measurement of winding resistance shall be done using the Transformer ohmmeter. Lead
connection shall be as shown in figure
Inference/Recommendation:
Winding resistance should be less than the guaranteed value (if any). Resistance of each phase
should be nearly equal from highest winding tap to lowest winding tap and same should in
descending order
Dos and Don’ts:
Cold resistance measurement shall not be made when the temperature is fluctuating rapidly. The
temperature of the windings shall be assumed to be the same as the average temperature of the
insulating liquid and the windings have been under insulating liquid with no excitation and with no
current in the from 3 to 8 hrs.
The current used for measurement shall not exceed 15% of the rated current of the winding whose
resistance is to be measured.
Polarity of the core magnetization shall be kept constant during all resistance readings.
Reading shall be taken only after attainting the steady state values.
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The voltmeter leads shall be independent of the current leads and shall be connected as close as
possible to the winding terminals tightly.
Frequency: Winding resistance test should be done half yearly basis/ routine maintenance/major
overhauling /emergency condition/ breakdown
TRANSFORMER TURN RATIO
Scope:
 To measure the turn ratio of the power transformer.

 As a base for assessing possible damage in the winding.
 To ensure proper crimping , brazing and other connections
Equipment required:
Recommended
S.NO Equipment
Range Accuracy
1 TRM PWR3A 110 volt 0.03
2 Multimeter 0-1000 volt +/- 0.5
Testing Procedure
 Remove the Neutral Earth Link of the transformer. The transformer should not be
connected to the system earthing.
 Ensure the terminals are properly cleaned & current terminal is clamped properly.
 Check the TTR set & earth it properly
 Tap changer to be operated (over its entire range, mechanically or electrically) at least
once prior to the test.
 Arrange the circuit as per diagram & Set the voltage ratio on the equipment (6:1 OR 3:1)
as per testing equipment.
 Take the reading (ratio) with every tap (from tap 1 to tap 17). Compare it with standard
result as per name plate specification
Page 31 of 333
Schematic Drawing
Confirmation of Test
If the result fulfilled the basic transformation equation N1/N2=V1/V2. With increasing the tap
from 1 to 17. The voltage change from -5 to +15 times respectively of the rated valve of the
primary side. Maximum Deviation +/- 2 % between different phases at same tap is accepted only.
Inference/Recommendation
Turn ratio is recommended during commissioning, tap changer replacement & after the major
overhaul of the transformer
Dos and Don’ts
While measuring the voltage supply at various terminals, supply voltage at HV terminal should not
be very high.
Frequency: Transformer turn ratio test should be done half yearly basis / routine maintenance /
major overhauling / emergency condition / breakdown
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CAPACITANCE AND TAN DELTA
Scope
 To ensure proper dryness of all active parts.

 To ensure clearance between windings and earth.
Equipment required
Recommended
S.NO Equipment
Range Accuracy
1 TAN DELTA 1 KV -11 KV 0.003 %
Testing Procedure
 De- energize , discharge the equipment which is to be tested as a safety precaution

 Remove the Neutral Earth Link from the transformer. The transformer should not be
connected to the system earthing.
 Connect the earthing lead to the transformer body. This earthing lead is to be connected
first and removed at last after all the tests have been done as a safety precaution.
 Check the earthing connections properly. The supply board should contain proper
earthing wiring.
 Short the HV leads (3 Terminals) and the LV leads (4 Terminals) of the transformer.
 Connect the HV lead to the kit.
 Connect the LV lead(s) to the kit. In case of two-winding transformer, only one lead
(say, the red lead) is to be connected. However, for a three winding transformer both the
LV leads are to be connected.
 Connect the Humidity and Temperature Sensor leads.
 Connect the Safety Strobe (Flash Light).
 Connect the PC interface and AC input supply to the kit and laptop. Connect the Safety
Switches. There are two leads – the longer lead is to be carried by the person climbing
the top of the transformer, whereas, the shorter one is be carried by the person standing
down. These two leads are provided for safety of personnel. During the test, these two
safety switches are to be kept pressed.
 Now start the test from laptop.
Page 33 of 333
Perform the test as follows
Ckt. Description
Test ID Line Configuration KV
B-Ref to 10 KV GND
a. CH+CHL RB 2 or 10
……………
b. CH …… GAR RB ………
……………
c. CHL ….... ………. ………
Schematic Drawing
Tan delta can be taken in three methods
 GST mode ("Grounded Specimen Test")

 GST + Guard mode
 UST mode ("Ungrounded Specimen Test")
 In GST mode, we measure the current flowing through the ground.
 In GST + Guard, a certain portion is guarded and we do not measure the current flowing
through it.
 In UST mode we do not measure the current flowing through the ground.
 In GST mode, once, the HV & LV leads are connected – the Cl portion is shorted and
we measure capacitance and tan delta with Ch&Chl in parallel. In GST + Guard mode –
Cl is shorted and the measurement of Chl is not taken. We only measure Ch value.
 In UST mode – the grounded portion: Ch&Cl is not measured and we only measure Chl.
Page 34 of 333
Capacitance
If the sum of CH (l –guard) and CHL (in UST mode) is equal to CH+CHL provided the results are
taken on the same scale of reference then the capacitance value is confirmed.
Tan Delta (Dissipation factor)
The value of tan delta should be ideally within 1% . Although a tolerance limit of - 100% to
+100% can be allowed for older transformers.
The di-electric loss of any insulating material is given by V2 C ω tanδ. If the dielectric loss is more
than the di-electric strength of the insulation would be reduced. In the ideal case the capacitive
current leads the voltage by 90 degree. But in practice, in all insulating system, there exists a loss
current Ir which is small in magnitude but in phase with the voltage. The total current I therefore
lead the voltage by an angle less than 90 degree. The angle by which it is less than 90 degree is also
known as loss angle delta. The test kit measures voltage current and power and with these
measurements the insulation power factor is determined. For a well processed insulation system, the
di-electric loss is low with a correspondingly low loss angle. When the loss angle is small then
cosØ is nearly equal to tanδ.
If the value of tan delta is more than the limit specified above then the subject transformer is kept
under observation. Higher value of tan delta indicates presence of moisture in the transformer. The
same test is performed again after 2 months and if the results deteriorate the following actions are
recommended.
I. DGA analysis
II. Induction heating recommended.
III. Oil filtration of main tank oil.
If the test results still do not improve then the transformer needs to be internally inspected or to be
sent for repair.
Dos and Don’ts
 Tan delta test is the test give the complete information about the insulation; it should be
performed on the transformer on the routine basis.
 Transformer should be discharged after completion of the test.
INSULATION RESISTANCE AND POLARIZATION INDEX
Page 35 of 333
Scope
 To ensure proper dryness of all active parts.

 To ensure clearance between windings and earth.
Reference
 IS-2026(Part 3)-1977-Clause 16.6

 ANSI/IEEE C-57.12.90-1999 – Clause 10.11
Equipment required
Recommended
S.NO Equipment
Make Range Accuracy
1 IR tester Megger Up to 10 T +/-3
Testing Procedure
 Confirm that equipment under test is de-energized & no parallel circuits are connected
to the equipment under test. In the case of neutral grounded equipment
(transformer/motor/generator) ensure that the ground connection to neutral is removed.
 Equipment terminals should have adequate clearance. Connecting leads shall be
properly insulated and as short as possible.
 In case transformer neutral star connection is opened and each phase winding shorted
and grounded.
 Connect the winding under test to 'L' terminal of the megger Connect 'E' terminal of
megger to Ground.
 In case of the digital battery operated megger set the test voltage and time before staring
the test.
 Apply the suitable voltage for 1 minute & repeat the test 2-5 times to get more accurate
value.
Absorption index and polarization index:
Total DC current IDC seen by the current coil of the megger in insulation resistance measurement
has the following four components.
IDC = IC+IA+I1C+I1S
IC = Charging current of the capacitance
Page 36 of 333
IA = Absorption current of the insulation
I1C = Conduction leakage current through the insulation
I1S = Surface leakage current
At beginning IC and IA components of current flow for several seconds or minutes depend upon the
size of the insulation, Magnitudes of these two components become zero after that. Remaining two
components of the current remain constant for a given applied voltage and are true indicator of
insulation condition.
Absorption index and polarization index values can be calculated as follows
Absorption index = (IR value after 60 seconds) / (IR value after 15 seconds) Polarization index =
(IR value after 600 seconds) / (IR value after 60 seconds)
Schematic Drawing
IR test is routine test of the switchgear while Polarization Index tests of switchgear conduct during
commissioning, overhaul and maintenance to get the condition of the insulation. Limit level of the
tests.
Equipment Minimum PI value
Rotating Machine 1.5

Transformer 1.3
IR value at least 1M per kV rating of the equipment.
Page 37 of 333
IR test is recommended after breakdown, overhauling & maintenance to get the condition of the
insulation while the PI test is conducted during commissioning or major overhaul of the equipment.
If the results satisfy the basic limits or the specification by the vendor then equipment is
recommended healthy for charging.
Dos and Don’ts
 Temperature difference between oil and ambient should not be greater than 2o C
 After completing the test all the terminal of the test object should be earthed for
significant time to allow any charge to negligible value.
 All metal part and bushing should be cleaned
 IR test is to be done before and after all the routine tests
Frequency: Tan delta & capacitance test should be done half yearly basis / routine maintenance /
major overhauling / emergency condition / breakdown
Transformer Oil Analysis
 Dissolved gas Analysis (DGA)

 IEC gas ratio analysis
 Dual Triangle method
GENERAL LIMITS OF TRANSFORMER OIL TEST
Page 38 of 333
Dissolved gas Analysis (DGA)
Dissolved gas analysis is the study of dissolved gasses in transformer oil.
The gasses produce due to
 Oxidation
 Vaporization
 Decomposition
During normal transformer operation, gasses are produced. But when there is a fault, the gasses are
produced in larger quantities. The gasses produced are proportional to the fault.
Most common faults and gasses produced in increasing severity
 Partial discharge or corona: Produces hydrogen gas (H2 (g)).

 Localized hot spots (Pyrolysis or thermal heating): At lower temperatures, it
produceCH4, C2H6 and at high temperatures, it produces a mixture is methane, C2H4
(ethylene), ethane and hydrogen gas.
 Arcing: produces a mixture of ethane acetylene (C2H2), ethylene, methane, and
hydrogen gas.
 The oil sample is analyzed in the laboratory using gas chromatography.
1. CHECK LIST FOR MAINTENANCE OF POWER TRANSFORMER -

ANNEXURE-PTR/MAIN/01
2. CHECK LIST FOR MAINTENANCE OF ON-LOAD TAP CHANGER-

ANNEXURE-PTR/OLTC/MAIN/01
Page 39 of 333
2. CIRCUIT BREAKERS:
A circuit breaker is an automatically-operated electrical switch designed to protect an electrical

circuit from damage caused by faults. Circuit breaker can be reset (either manually or
automatically) to resume normal operation.
OPERATING PRINCIPLE
Under fault conditions, current intensity increases multiple times the normal current flow. This
current senses by relay and energized tripping coil of breaker to isolate the system. Circuit breaker
also used to isolate the section manually
Type of circuit breakers used in DHBVN
At 33 KV level
1. Oil circuit Breakers
2. Vacuum circuit breaker
At 11 KV level
1. Vacuum circuit breakers
CIRCUIT BREAKER RATING:

The breaking capacity of a circuit breaker depends on
(i) Symmetrical breaking capacity

(ii) Asymmetrical breaking capacity
Symmetrical breaking capacity
It is the rms. Value of the ac component of the fault current that the circuit breaker is capable of
breaking under specified conditions of recovery voltage.
Asymmetrical breaking capacity
It is the rms value of the total current comprising of both ac and dc components of the fault current
that the circuit breaker can break under specified conditions of recovery voltage.
Making Capacity of circuit breakers
The rated making current is defined as the peak value of the current (including the dc component) in
the first cycle at which a circuit breaker can be closed onto a short circuit.
Short-time Current Rating

The circuit breaker must be capable of carrying short-circuit current for a short period while another
circuit breaker (in series) is clearing the fault. The rated short-time current is the rms value (total
Page 40 of 333
current, both a.c. and d.c. components) of the current that the circuit breaker can carry safely for a
specified short period.
Testing of circuit breakers
 BREAKER TIMING
 CONTACT RESISTANCE MEASUREMENT
BREAKER TIMING
Scope:
To measure CLOSE, OPEN & CO timings of the breaker.
Reference:
 IS-14658:1999 IEC-62335
 IS/IEC-60947
Equipment Used:
Recommended
S.NO Equipment Range Accuracy
1 SCOT MXP 0.1 Volt-1000 Volt 0.01%
Testing Procedure:
 De- energize, discharge the equipment which is to be tested as a safety precaution. .

 Check whether Timer leads and associated clips that are to be connected to the breaker
poles are good & tight.
 Make the test connections on the lines of circuit diagram
 Switch on the power supply to the timer and issue Close command from the timer. Note
down the close timing displayed on the timer
 After recommended time interval (3 seconds), issue Open command from the timer.
Note down the open timing displayed on the timer.
 Now issue Close-Open (CO) command from the timer. Note down the CO timing
displayed on the timer.
Page 41 of 333
Schematic Drawing:
Confirmation of Test:
 Breaker opening time should be less than the closing time of the breaker, it should
come in the range of 30-45 ms. while closing time should be 40-60 ms.
 CO- time breaker should at the middle of the closing and opening time.
 Opening time < closing -Opening time < closing time
 Please refer GTP Details of the Breaker for confirmation of the Timing Results.
If the specimen breaker satisfies the respective condition then the respective breaker is considered
to be satisfactory. If any deviation is observed from above mentioned condition then corrective
action should be taken with the help of the manufacturer /OEM.
CONTACT RESISTANCE MEASUREMENT
Scope:
 To ensure minimum resistance between two contacts.

 To get the resistance of breaker in close position for examine condition of the moving
and fixed contact.
Page 42 of 333
Reference:
 IS-14658:1999 IEC-62335
Equipment Used:
S.NO Equipment Range Accuracy
1 Contact resistance meter 10 micro ohm to 100 m-ohm (+/-) 3 %
Testing Procedure:
 De-energize and discharge equipment which is to be tested as a safety precaution.

 In case of the breaker make sure that Breaker/ isolated is isolated and kept in closed
condition.
 Make all the contact clean & connect current / voltage lead as shown below
Schematic Drawing:
Contact resistance test is conduct during commissioning, overhaul and maintenance of

switchgear (Breaker) to ensure the minimum resistance of the contact.
Contact resistance measurement is recommended for measurement of resistance between contacts

of the breaker/ Bus Bar which should be as minimum as possible, because as the resistance
increases I2R losses will increase which will overheating and pitting of the contacts. It should come
in the range of micro ohm.
Page 43 of 333
** Breaker /Isolator maintenance /repair is recommended if the variation is 50 % isobserved
w.r.t commissioning results.
Dos and Don’ts:
 Contact should be cleaned properly before testing.

 Repeat the same procedure for getting more accurate results.
CHECK LIST FOR MAINTENANCE OF 33 & 11KV CIRCUIT BREAKERS - ANNEXURE-

CB/MAIN/01
3. CURRENT TRANSFORMERS:
A current transformer (CT) is a type of instrument transformer designed to provide a current in

its secondary winding proportional to the alternating current flowing in its primary. They are
commonly used in metering and protection circuits
Principle
The current transformer works on the principle of variable flux. In the "ideal" current transformer,
secondary current would be exactly equal (when multiplied by the turn’s ratio) and opposite of the
primary current
Page 44 of 333
Design
There are two basic types of current transformers: wound and toroidal. Wound current transformers
consist of an integral primary winding that is inserted in series with the conductor that carries the
measured current. Toroidal or donut-shaped current transformers do not contain a primary winding.
Instead, the wire that carries the current is threaded through a window in the toroidal transformer.
The most common design of CT consists of a length of wire wrapped many times around a silicon
steel ring passed over the circuit being measured. The CT's primary circuit therefore consists of a
single 'turn' of conductor, with a secondary of many hundreds of turns.
Common secondary’s are 1 or 5 amperes. For example, a 400:5 CT would provide an output current
of 5 amperes when the primary was passing 400 amperes. Typically, the secondary connection
points are labeled as 1s1, 1s2, 2s1, 2s2 and so on, or in the IEEE standard areas, X1...X5, Y1...Y5,
and so on. The multi ratio CTs are typically used for current matching in current differential
protective relaying applications.
C T MANGETISING CHARACTERISTICS:
The working range of a protective CT extends over the full range between the ankle and the knee
points and beyond, whereas the measuring CT usually operates in the region of the ankle point.
The major difference in requirement between those for metering and those for protection is that
with the former, specified accuracies are essential over a range of primary current about 5% full
load Upto 125%. Whereas the protective purposes, we are concerned with accurate secondary
reproductions of the primary currents from about full load upto those of short circuit magnitude, the
latter being many times full load. It is therefore a primary requirement, that protective CTs should
have a high saturation level. Whereas those for metering should preferably saturate at low level,
thus protecting the connected instruments or meters against over currents.
The point at which a CT begins to saturate is known as the knee point on the curve of its
magnetizing characteristic and is by definition, the point where the exciting current increases by
50% for a 10% increase in secondary voltage typically as shown in figure.
Page 45 of 333
10% Increase in
secondary voltage
SECONDARY VOLTAGE
KNEE
POINT
50% Increase in
exciting current
TESTS FOR CURRENT TRANSFORMER
 POLARITY TEST
 KNEE POINT TEST
 INSULATION RESISTANCE OF CURRENT TRANSFORMER
POLARITY TEST
Scope:
To measure ratio of current transformer; potential transformer.
Reference:
ANSI/IEEE C-57.12.90-1999 - Clause 6.2

Equipment Used:
Recommended
S.NO Equipment
Range Accuracy
1 DC source ( 1.5 to 6 V Dry Cell-1 or 2 ) 1.5 Volt-6 Volt
2 Multimeter 0.02 volt -1000 volt 0.003
Testing Procedure:
Page 46 of 333
 Connect as per the diagram. In the case of tapped secondary windings, the full winding
to be considered.
 Close the switch momentarily (for a second) and open. Observe the deflection of the
meter and note whether it is positive or negative.
 If it shows positive value for the given connection, then the marked polarities are
correct. Marked polarities can be concluded incorrect if it shows a negative value
Schematic Drawing
 If the meter show positive valve then the polarity of the CT is appropriate if meter
shows any negative valve then few corrective action can be taken out
 If the test is carried out on the terminals of the CT junction box, repeat the test on the
direct CT terminals after the disconnection of associated wiring. If the marked
polarities are correct at the CT terminals, then the associated wiring up to the junction
box to be rectified and repeat the test after rectification.
 If the marked polarities are wrong at the CT terminals, reject the CT and inform the
concerned Maintenance Engineer for necessary rectification.
 Repeat the test after the rectification
If the specimen breaker satisfies the respective condition then the respective breaker is considered
to be satisfactory. If any deviation is observed from above mentioned condition then corrective
action should be taken with the help of the manufacturer or vendor.
Page 47 of 333
Dos and Don’ts:
Contact should be cleaned properly before testing. Battery source of proper value should be used.
KNEE POINT TEST
Scope:
The main purpose of knee point voltage is to identify the core saturation characteristics.
Reference:
 1EC60044-1 2003-02
 IS 2705
Equipment Used:
 Slide regulator, 5 A, 230 V. Use step up transformer to raise up output voltage.

Voltmeter
 Ampere meter
 Cable connection 2.5 mm2
Schematic Drawing:
Testing Procedure:
 Connect the circuit as shown as figure above

 Primary winding and other(s) secondary winding is left opened.
 Raise the voltage source step by step and record the voltage and current as table.
 If current already reached to the nominal secondary current, the test is stopped
Page 48 of 333
 On applying the voltage at current should increase in the same proportion. If current
increases 50 % on increase the voltage by 10% that it is considered Knee point of the
CT’s core.
 Generally Knee point voltage of CT cores is as below
 20 -80 voltage for metering Class core

 150 -750 voltage for protection class core
Measurement of knee point voltage is very essential for both metering and protection. Higher knee
point voltage of meter core CT could cause of burning of meter in the same way low knee point
voltage in protection would cause of unwanted tripping.
INSULATION RESISTANCE OF CURRENT TRANSFORMER
Scope
To ensure proper dryness of all active parts of current transformer. To ensure clearance between
windings and earth.
Reference
 IS-2026(Part 3)-1977-Clause 16.6

 ANSI/IEEE C-57.12.90-1999 – Clause 10.11
Equipment required
Recommended
S.NO Equipment
Range Accuracy
1 IR tester Up to 10 T +/-3
Page 49 of 333
Testing Procedure:

 Equipment terminals should have adequate clearance. Connecting leads shall be
properly insulated and as short as possible.
 Connect the core winding of current transformer to 'L' terminal of the insulation tester
& Connect 'E' terminal of insulation tester to Ground.
 In case of the digital battery operated insulation tester set the test voltage and time
before staring the test.
 Apply the suitable voltage for 30 sec & repeat the test 2-5 times to get more accurate
value. All primary to secondary, primary to earth test shall be conducted on 5 KV &
core to core test on 500 volt insulation tester.
 IR test is routine test of the current transformer, it is also recommended during

commissioning, overhaul and maintenance to get the condition of the insulation.
 IR value at least 1M per kV rating of the equipment.
IR test is recommended after breakdown, overhauling & maintenance to get the condition of the
insulation. If the results satisfy the basic limits or the specification by the vendor then equipment is
recommended healthy for charging.
Dos and Don’ts
Page 50 of 333
 After completing the test all the terminal of the test object should be earthed for
significant time to allow any charge to negligible value.
 IR test is to be done before and after all the maintenance.
CHECK LIST OF CURRENT TRANSFORMER
Visual Inspection: Current transformers are normally filled with oil and have oil impregnated
paper insulation for both primary and secondary winding. Careful inspection is to be made for any
trace of oil leakages. Oil leakages are more prone through cemented joints or secondary terminal
box due to improper sealing of terminal studs.
Visual inspection is also to be carried out on the healthiness of terminal connections, condition of
porcelain, development of cracks, chippings, cleanliness of insulator surface etc.
Maintenance of Gaskets: Marshaling boxes, CT terminal boxes are to be properly sealed to

prevent any dust, rain water and insects. Door gaskets are to be changed periodically to give proper
sealing. All door bolts/ latches are to be properly tightened and never left loose.
Secondary Terminals Connections: Stud type terminals are preferred in Marshaling box cable
terminals. This gives better grip even if more than one wire is connected to one terminal. But pin
type terminals are also provided in some cases. Since wires may get loose due to vibration, climatic
condition, it is required to check tightness of terminals periodically to avoid mal-operation/ non
operation due to improper contacts. All terminals of unused CT secondary terminals are to be
properly shorted to avoid development of abnormal voltage and subsequent failure of CTs in case
they are left open. The tan∂ test tap is to be properly earthed to avoid damage to insulation.
Primary Terminals: Thermo vision scanning indicates proper connection of primary terminal. If
thermo vision is not carried out, physical checking of terminal connection is to be done with proper
torque. As CT primary carries heavy current, any loose joint may lead to arcing and welding of
terminal connectors.
In industrial areas where pollution levels are high, due to saline atmosphere/ chemical
contamination, porcelain insulators of electrical equipment shall have higher creepages.
CHECK LIST FOR MAINTENANCE OF CURRENT TRANSFORMERS

ANNEXURE-CT/MAIN/-01
4. POTENTIAL TRANSFORMERS
Voltage transformers (VT) or potential transformers (PT) are another type of instrument
transformer, used for metering and protection in high-voltage circuits. Typically the secondary of a
voltage transformer is rated for 110 V at rated primary voltage, to match the input ratings of
protective relays.
Page 51 of 333
Testing of potential transformer
RATIO TEST
Scope:
To ensure voltage ratio of test on PT / CVT.
Reference:
 IEC 60044-1
 IEEE C57.13 standard requirements for instrument transformers
Equipment Used:
Recommended
S.NO Equipment
Range Accuracy
1 1Ø variac 0-260 V +/-3
2 Voltmeter 650 V +/-2
Testing Procedure:
Make the connections as in drawing for PT. Ensure the secondary cores are kept open circuited.
Switch on the supply and gradually increase voltage up to 200 V (VP) Record corresponding
Page 52 of 333
secondary voltage (VS) on all available cores. Compute actual Ratio =VP/VS and compare that
with expected values. Compute the deviation for all cores. Repeat the test on PTs on other phases.
Schematic Drawing:
Ratio test is a routine test of the potential transformer, ratio test is recommended during
overhaul and maintenance to check the expected ratio of potential transformer. Limit
level of the tests is +- 3 %.
Inference / Recommendation:
Measurement of ratio test is very essential for potential transformer. Error in ratio test has
significant effect on metering and protection circuit. It is recommending that ratio error in
potential transformer shall be in the limit during every checkup.
CHECK LIST FOR MAINTENANCE OF POTENTIAL TRANSFORMERS-
ANNEXURE-PT / MAIN / 01
5. LIGHTNING (SURGE) ARRESTERS:
Lightning is one of the most serious causes of over voltage. A lightning rod provides a
cone of protection, which has a ground radius approximately, equal to its height above
the ground. The typical lightning arrester also known as surge arrester has a high voltage
terminal and a ground terminal.
Page 53 of 333
LA voltage rating Corresponding to the system voltage
ARRESTER RATING IN
RATED SYSTEM HIGHEST SYSTEM
KV FOR EFFECTIVE
VOLTAGE (KV) VOLTAGE (KV)
EARTHED SYSTEM
11 12 9
33 36 30
66 72.5 60
132 145 120/132
220 245 198/216
400 420 336
Surge Arrestors installed in the substation are intended to divert surges to earth and thus protect
costly switchyard equipment. Proper insulation coordination is necessary for enhancing life span of
costly substation equipment.
Page 54 of 333
Surge Arrestors are monitored basically using three tests to evaluate their condition. Leakage
current monitoring, Insulation resistance measurement and thermo vision scanning would indicate
any deterioration in surge arresters. Out of these, leakage current measurement and thermo-vision
scanning are on-line measurement and shut down is required for IR measurement. As system
availability is crucial for utilities, more emphasis is to be given for on-line measurements.
Leakage Current Measurement:
As per IEC-60099(5), the following condition monitoring techniques for the surge arresters in
service are suggested:
 Total leakage current measurement

 Watt loss measurement
 Insulation resistance measurement
 Third harmonic resistive current (THRC) monitoring with compensation for third
harmonics in system voltage.
CHECK LIST FOR MAINTENANCE OF LIGHTNING (SURGE) ARRESTERS-

ANNEXURE LA / MAIN / 01
Page 55 of 333
6.
ISOLATORS & EARTH SWITCHES
Disconnectors have main current carrying arms and operating mechanism for connection and
disconnection. Being off-line devices, they are normally air break type. Normally horizontal double
break, Horizontal center break, Pantograph, Vertical break Disconnectors are in use in EHV
substations.
The alignment of Disconnectors is very important for smooth operation. The limit switches, the
healthiness of auxiliary contacts needs to be checked periodically. The main contacts are to be
inspected and made smooth if any pitting marks seen. All moving parts are to be lubricated for
smooth operation. The gear mechanism and motor normally do not require any maintenance and
manufacturer's' recommendation should be referred for maintenance of gears.
Earth Switches:
The earth switch is a safety device and smooth operation is to be ensured by proper alignment. The
earth blade contacts are to be cleaned properly for proper contact and contact resistance to be
measured to ensure healthiness. The earth connection from blade to earth is to be carefully checked.
All the joints should be tightened. Flexible copper braid connections are provided and healthiness
ensured. All moving parts should be lubricated for smooth operation.
CHECK LIST FOR MAINTENANCE OF LINE ISOLATORS & EARTH SWITCHES -

ANNEXURE-ISOL / MAIN / 01
Page 56 of 333
7. BATTERY AND BATTERY CHARGERS:
In substation DC supply has equal importance. All protection & indication circuits enable with DC
supply only. Substations generally use Lead Acid batteries / Nickel-Cadmium batteries for DC
supply. Now a days valve regulated lead acid batteries (maintenance free batteries) are also in use
for substation applications.
Cell containers are to be kept always clean to avoid surface leakage. Any leakage is to be attended
immediately. Vaseline J white petroleum jelly is to be applied on battery terminal and inter-cell
connectors, nuts and bolts to avoid sulphate deposit. The rubber seal at the base of the terminals and
on cell lid is to be fitted properly and to be replaced if damaged. All connections are to be checked
for tightness.
Battery Chargers:
Battery charger is to be maintained for keeping the battery always charged and also to supply
normal DC load for operation.
Rating of Battery bank along with VA capacity used
BATTERY CHARGER DETAIL USED IN DHBVN

VOLTAGE LEVEL VA CAPACITY OPERATING VOLTAGE
33 KV 150 24 Volt/ 50 Volt
* Each cell capacity =2 volt

Battery Capacity Testing:
Page 57 of 333
Initial Requirements:
The following list gives the initial requirements for all battery capacity tests
 Check all battery connections and ensure that all connections are proper and clean.
 Record the specific gravity and float voltage of each cell just prior to the test.
 Record the electrolyte temperature of 10% or more of the cells to establish an average
temperature.
 Record the battery terminal float voltage.
 Take adequate precautions (such as isolating the battery to be tested from other
batteries and critical loads) to ensure that a failure will not jeopardize other systems or
equipment.
Discharge Test: The ampere-hour capacity of a battery varies with the rate of discharge. The
capacity is more at slower rates of discharge and less at higher rate of discharge. The Indian
Standards adopt 10 hr. rate as the standard rate of discharge for specifying the AH capacity of
stationary batteries.
 Disconnect the charging source, connect the load bank to the battery, start the timing,
and continue to maintain the selected discharge rate.
 Maintain the discharge rate until the battery terminal voltage decreases to a value equal
to the minimum average voltage per cell as specified by the design of the installation
(e.g. 1.75 V) times the number of cells.
 Read and record the individual cell voltages and the battery terminal voltage. The
readings should be taken while the load is applied at the beginning of the test, at
specified intervals, and at the completion of the test. The readings are to be taken on
hourly basis.
 If one or more cells is approaching reversal of its polarity (+ 1 V or less) and the test
nears the 90-95% expected completion time, continue the test until the specified
terminal voltage is reached.
 If earlier in the test an individual cell is approaching reversal of its polarity (+ 1 V or
less) but the terminal voltage has not yet reached its test limit, the test should be
stopped, and the weak cell should be disconnected from the battery string and bypassed
with a jumper of adequate conductor capacity. The new minimum terminal voltage
should be determined based on the remaining cells. The test should then be continued in
order to determine the capacity of the remaining cells. The time required disconnecting
the cell, installing the jumper and restart the test shall not exceed 10% of the total test
duration or 6 min, whichever is shorter. This "downtime" shall not be included in the
test discharge period (i.e., the capacity determination shall be based on the actual test
time).
CHECK LIST FOR MAINTENANCE OF BATTERY BANK & BATTERY CHARGERS

ANNEXURE-BAT / MAIN / 01
Page 58 of 333
8. 11 KV VCB CONTROL AND RELAY PANELS
A circuit breaker is an automatically-operated electrical switch designed to protect an electrical
circuit from damage caused by faults. Circuit breaker can be reset (either manually or
automatically) to resume normal operation.
OPERATING PRINCIPLE
Under fault conditions, current intensity increases multiple times the normal current flow. This
current senses by relay and energized tripping coil of breaker to isolate the system. Circuit breaker
also used to isolate the section manually
11 KV bus and outgoing 11KV outgoing feeders supply voltage to field via VCB circuit breakers
connected with 11KV bus. Control panels are basically the monitoring & operation unit in a grid
substation. It is used for operation & monitoring purposes.
Following activates shall be monitored at C&R panels
 CB ON
 CB OFF
 Spring Charge
 L/R Switch Position on C&R Panel
 Protection Operated by Trial Tripping from Relay
 Common trip circuit healthy logic
 Trip Circuit Healthy
 Trip Circuit Healthy for 86
 DC /AC Failure Indication, operating of DC fail relay (80)
CHECK LIST FOR CONTROL PANEL-

ANNEXURE-CONTROL PANEL/MAIN/01
Page 59 of 333
9. 33 KV CONTROL & RELAY PANELS
33 KV relay & control panels are used to operate 33 KV outdoor circuit breakers. It also used to get
all the monitoring information like breaker on /off status, spring charge, local remote status, trip
circuit healthy information, DC & AC voltage related information etc.
33 KV control panels also include relays for protection & master trip relays also.
CHECK LIST FOR CONTROL PANEL-

Page 60 of 333
10. 33 KV OUT DOOR BUS
33 KV outdoor bus is used to connect incoming lines, power transformers, and outgoing lines etc.
33 KV outdoor bus works as the most visual architecture of a grid substation to interconnect various
substation equipment.
CHECK LIST FOR 33 KV OUT DOOR BUS -

ANNEXURE-33KV BUS/MAIN/01
11. 11 KV INDOOR BUS

11 KV indoor bus system includes circuit for LT side of power transformer to 11 KV bus system.
11 KV bus includes 11 KV incomer as the source of power and outgoing feeders as supply source
of energy to the system.
The size of the bus-bar is important in determining the maximum amount of current that can be
safely carried. The bus-bar should be able to carry the expected maximum load current without
exceeding the temperature limit. The capacity of bus should also be checked for maximum
temperature under short circuit conditions. Different types of bus-bars, are used in a substation in
accordance with the safety and reliability considerations.
CHECK LIST FOR 11 KV OUT DOOR BUS -

ANNEXURE-11 KV BUS/MAIN/01
12. APFC PANELS ( AUTOMATIC POWER FACTOR CONTROLLERS)
APFC consists of a number of capacitors that are switched by means of contactors. These
contactors are controlled by a controller that measures power factor in an electrical network.
Depending on the load and power factor of the network, the power factor controller will switch the
necessary blocks of capacitors in steps to make sure the power factor a selected value. Power factor
reduce due to high inductive load in system. Presence of this high inductive load power factor
reduces.
Generally on any supply system power demand is varying, power factor also varies as a function of
load requirement. Hence it is difficult to maintain consistent power factor by using fixed
compensation i.e. fixed capacitors. Thus under light load condition it may cause leading power
factor, which results over voltage, Saturation of transformer, Mal-operation of relays, Penalty by
electrical authority .
CHECK LIST FOR APFC CONTROLLERS -
ANNEXURE-11 KV APFC /MAIN/01
Page 61 of 333
13. ACDB (AC-DISTRIBUTION BOARD):-
AC supply is required at grid substation for various purpose. It includes.
 Supply to ac motor of breakers.
 Charging of battery banks
 Switch yard lighting system.
 Panel lighting system.
 Sources of supply for grid auxiliaries.
Normally a local transformer is used for such type of supply. Also a temporary sources also
available at grid level to supply in case of maintenance of local transformer.
CHECK LIST FOR AC distribution Board -

ANNEXURE-ACDB /MAIN/01
EARTHING SYSTEM AT SUBSTATION
An earthing system in a sub-station is to provide under and around the sub-station a surface which
shall be at a uniform potential and near zero or absolute earth potential as possible .This provision
ensures that no human being in sub-station is subjected to a shock or injury on occurrence of a short
circuit or development of other abnormal conditions in the equipment
Installed in the yard.
Ground mat is provided below ground level. Earth electrodes are driven into ground at several
points and are connected to grounding mat to form earth mesh. All the structures, Transformers &
other power equipment are connected to this mesh by galvanized steel strips (40x5 mm).
Earth Electrodes is a metal plate, pipe or a conductor electrically connected to earth. Copper,
Aluminum, mild steel, galvanized iron are generally used for electrodes.
Generally 40mm dia, 2.6m long GI/MS rods are used
EARTH MAT:
It is formed by steel 75/8 flats laid horizontally at a depth of 0.5 m below surface of ground to form
a mesh of rectangular formation & are welded together. The spacing of earth rods is determined by
required touch & step potential. In addition to earth mat, earth electrodes are used these are also
connected to the mesh. Solid bar risers are welded to mesh and brought up near the equipment
foundations.
BASIS FOR DESIGN OF GROUNDING SYSTEM
 Magnitude of fault current
Page 62 of 333
 Transient Over voltage
 Lightning Protection
 Application of Protective devices for selective ground fault protection
 Type of load served viz. Motor, Generator etc.
GENERAL GUIDELINES FOR EARTHING
An effective grounding system must satisfy the following conditions:
 Provide a low impedance path to ground for personnel and equipment safety.
 Withstand and dissipate repeated faults and surge currents
 Provide ample corrosion allowance to various chemicals to ensure continuous service during
life of the equipment being protected.
 Provide rugged mechanical properties for easy driving of earth electrodes with minimum
difficulty.
 All non-current carrying metal parts associated with installation shall be effectively earthed
to a grounding system or mat which will limit the touch and step potential to tolerable
values.
BASIC REQUIREMENT FOR EARTHING:

 The current carrying path of earthing system should have enough capacity to carry
maximum fault current.
 The resistance of earth & current path should be low enough so as to prevent voltage rise
between N & E.
 Step & Touch potential should be within the safe limits.
 Systematic survey of earth resistivity should be carried out.
 The earth electrodes should be driven in the ground to a sufficient depth.
 To obtain sufficient low earth resistance ,
 The area of earth mesh is increased.
 The spacing of buried rods is reduced.
 Soil is kept wet.
 The number of earth electrodes are increased.
 Earth resistance is reduced by means of Nacl (Common salt), CaCl2 (Calcium chloride),
Na2CO4 (sodium carbonate), CuSO4 (Copper Sulphate), charcoal, soft coal etc.
PARAMETERS AFFECTING THE DESIGN OF EARTH MAT

 Magnitude of fault current
 Duration of fault
 Soil resistivity
 Resistivity of surface material
Page 63 of 333
 Shock duration
 Material of earthing mat conductor
 Earthing mat geometry
 Copper – Mostly used for grounding as it is less prone to corrosion and has better
conductivity.
FACTORS DETERMINING SOIL RESISTIVITY
 Different type of soil has different resistivity.

 Clay Soil: 4 to 150 Ohmmeters
 Rocky or Gravel soil: Above 1000 Ohmmeters
Effect of Moisture
Moisture has a great influence on resistivity value. Resistance drops quickly to minimum steady
value at 15% moisture. After that it has a little affect.
Effect of Dissolved Salts in water:

Soil resistivity also depends upon amount & nature of salts dissolved in water. A small quantity of
dissolved salt reduces the resistivity considerably.
A small quantity of salt i.e. 1 to 2% of moisture by weight drops the resistivity by 80%.
Salts can be Common salt (Sodium Chloride- NaCl); Calcium Phosphate; Calcium Chloride
(CaCl2); Copper sulphate (CuSO4) & Sodium Carbonate (Na2CO3) .Common salt is most effective
in improving conductivity of soil, but has corrosive effect.
Soft Coke & Charcoal used in combination with Salt & water.
Effect of Temperature
Soil resistivity decrease sharply with decrease in temperature below 0 OC. It signifies need of
burying electrodes deep.
Method of improving Grounds:
 Increasing number of electrodes, creating parallel path.

 Increasing depth of driven rod (2.44 m is economical depth).Volume of soil contact
increases. Moisture contact at depth also increases.
Page 64 of 333
 Increasing size of driven rod.
 Soil treatment with salts. These are effective up to the soil of resistivity 300 ohm
meters. After that other methods are used. One of the most suitable substance for
chemical treatment of soil of very high resistivity for reducing the earth resistance is
Natural Clay, also called Bentonite. It is non corrosive, stable & has a resistivity of 2
Ohm.m at 300% moisture.
MAXIMUM ACCEPTABLE VALUE OF E. RESISTANCE: 0.1 to 10 Ohms.
 Power Stations: 0.5 Ohm (220KV & ABOVE)

 EHT Sub-stations: 1.0 Ohm (66 KV to 132 KV)
 Small Stations: 2.0 Ohms (33 KV level)
 Distribution Transformer structure: 5 Ohms (11 kV & below)
 Tower foot structure: 10 ohms
CHECK LIST FOR MAINTENANCE OF EARTHING SYSTEM AT GRID SUBSTATION
ANNEXURE-EARTHING/MAIN/01
Page 65 of 333
33 KV Transmission lines
In DHBVN, HVPNL is the main source of supply, all 33 KV lines come to substations via rail or
RCC pole structure.
Following conductors have been used
RATED CURRENT
CONDUCTOR MVA LOADING (33 KV
S. NO. AREA UNDER NORMAL
TYPE LEVEL)
CONDITION
1 WOLF 150 532 26.6

2 LEOPORD 130 386 19.3
3 DOG 100 368 18.4
4 RACCOON 80 344 17.2
5 RABBIT 50 251 12.55
6 WEASEL 30 186 9.3
ITEMS USED IN 33 KV LINES
 PCC Pole 11.0M Long.

 ACSR Conductor 150mm2
 33 KV Pin insulators with pin
 11 KV Disc insulators 45KN B&S type
 Disc Fitting B&S type
 Single Tension Fittings for 130mm2 ACSR Conductor
 Suspension Fittings for 130mm2/ 150 mm2 ACSR conductor
 U- Bolt for suspension Fitting
 PG Clamps for 130mm2 / 150 mm2 ACSR conductor
 33 KV Top Brackets / hamper
 MS X Arm (Single Pole) 100x50x6 mm (2200mm)
 M.S. Channel (X-Arm) 100x50x6mm 3050mm (for H pole)
 M.S.Channel 75x40x6 3350mm (for earth wire)
 M.S. Angle 50x50x6mm-2860mm (Bracing H. Pole)
 M.S Angle 50x50x6mm-2200mm (Belting for H-pole)
 Half Clamps
 Full Clamps
Page 66 of 333
 Stay Sets 8' long complete with X-Plat 460mm of Angle 65x65x6 Elbow & rod with
Disc
 Stay wire 7/8 SWG
 G.I. Pipe 40 mm dia 6 mtr. Long for earthing
 Earthing with Earth rod as per Drawing
 GSL 8 SWG
 MS Nuts & Bolts
 Danger Plates (Enameled)
 Number Plates (Enameled)
 Phase plate for each phase set of 3 (on each H-Pole & 4-Pole)
 Eye Screw Bolts 9”x5/8"
 Barbed Wire
 "G.I. Strip 25x6 mm 9 meter. For earthling
 Knee Bracing - MS Flat 50x6
 Catenary wire 7/14 SWG
 CI pipe 250 mm diameter 14 mm thick for highway crossing
 S/C 630mm2 33kV XLPE cable
 End termination kit for S/C 630 sq. mm Cable
 33KV Isolators (630 Amps), with clamps
 ACSR Conductor 150mm2 (Leopard)
 33 KV AB cable 3 Core 185+240 mm2
 End termination kit for AB cable 3 Core 185+240 mm2
 Dead end calm p assembly with eye hook
 Trench (with angle and MS sheet cover) for laying 33 KV XLPE cable in yard
TYPE OF PROTECTION USE AT 33 KV LINES

A three phase O/C and E / F & directional relay shall be used as a backup of main protection of
line. This relay shall have the following features:
 Non Directional (50/51 & 50N/51N) OR Directional O/C and E/F (each element shall
have one IDMTL and three high set definite time relay) (67 R, Y, B and 67N)
 Negative sequence current (unbalance current) (46)
 Overload relay (49).
 VT supervision relay and Trip circuit supervision relay.
 Integrated CB failure protection.
 Configurable LEDs shall also be provided to indicate the relay operation and the alarm
/ status change of a bay equipment e.g. Phase Fault operated / Earth Fault operated/CB
open / CB close / spring charge etc.
Page 67 of 333
Electrically reset type high speed, heavy duty relay shall be used for tripping on operation of
main protection relays of the Line. The two trip coils where ever provided shall be provided with
independent potential free contacts from different fused DC supplies .Trip relay shall be
supervised
MAINTENANCE OF 33 KV LINES
Normal ground patrolling of lines should be conducted by lines maintenance crew periodically.
Periodicity will be decided on the basis of importance of the line, terrain condition, and proximity
of the line to habitations, forests, gardens, water borne areas etc. and environmental impact on the
line.
During ground patrolling of the line, the patrolman should check for the following
 Location no; type of poles (PCC/Rail pole etc.), location address.

 Clearances of the line, both to ground and in air.
 Availability of all poles and their condition. Obstructions in the proximity of the line
(within line corridor) like trees, branches, structures etc. location wise should be noted.
 Observing the condition of insulators, conductors, earth wire, jumpers, clamps,
dampers, spacers etc., with binoculars, from ground level/nearest possible elevated
level.
Special patrolling of the line should be done after momentary tripping of the line on fault, for any
defects. Defects noticed shall be rectified immediately if this can be attended while the line is live
or at the earliest by availing shutdown, anyway, before the defect develops into a major one causing
breakdown. Proper planning of materials and manpower is required in order to carryout rectification
under shutdown in minimum time to avoid/minimize interruption to loads.
Break down maintenance: When a permanent/semi-permanent fault occurs on the line, the line
may break down causing interruption of longer duration. The faults could be snapping of
conductors, disconnection of jumpers, cross-arms/ pole twisting or pole collapse with or without
damage to foundation. This may be due to various reasons like heavy wind due to storms,
weakening of pole due to aging, accidents, thefts etc.
Condition Monitoring Procedures

Condition monitoring is useful in identifying some of the defects on conductor and insulators,
which is not possible through visual ground inspection. Assessment of nature of defect helps in
taking preventive action. Possible breakdowns due to defective joints, punctured insulators etc. can
be avoided.
Page 68 of 333
Various condition monitoring methods are:
On Line Techniques – Coronagraphy
-- Thermo vision scanning
Off Line Techniques-- Pollution measurement of insulators
-- IR measurement of insulators
-- Contact resistance measurement
BEST PRACTICES FOR PERSONNEL SAFETY
Electrical Safety Clearance (Live Metal clearance)

Rated Voltage Safety Clearance (meters)
Up to 33kV 0.8
66kV 1
MINIMUM CLEARANCE (IN M) BETWEEN LINES WHEN CROSSING

EACH OTHER
MINIMUM CLEARANCE (IN M) BETWEEN LINES WHEN CROSSING

EACH OTHER
110-132 220 400 800
11-66 KV
KV KV KV KV
LOW AND
2.44 3.05 4.58 5.49 7.94
MEDIUM
11-66 KV 2.44 3.05 4.58 5.49 7.94
110-132 KV 3.05 3.05 4.58 5.49 7.94
220 KV 4.58 4.58 4.58 5.49 7.94
400 KV 5.49 5.49 5.49 5.49 7.94
800 KV 7.94 7.94 7.94 7.94 7.94
Page 69 of 333
CHECK LIST FOR MAINTENANCE OF 33 KV LINES
ANNEXURE-33 KV LINES /MAIN/01
GUARDING SYSTEM
Guarding means safe guard. This is below the line. In case of conductor snapping, it will touch the
guarding wire before laying on ground or will lay on guarding. The guarding is always earthed. The
line protection will operate and will switch off the line. Snapped conductor will not remain charged.
Page 70 of 333
In absence of guarding, conductor will fall on ground and as no protection is operated, conductor
will remain charged. This will cause accidents. Hence the guarding is very essential.
Types of Guarding:-
 P. V. C. Guarding.
 Lecing guarding.
1. P.V.C. Guarding:
This is mainly used for L. T. Lines passing through agriculture field. This is used where formation
of line is vertical. The upper end is tied in shackle bolt and lower end is tied to the neutral. A G.I.
wire frame is prepared so that there will be horizontal G.I. wire piece at equal distance below every
conductor. The vertical wires of the frame are insulated with P.V.C. pipe. Even conductor swings, it
will not be earthed due to P.V.C. pipe. In case of snapping of conductor, it will make contact with
the G.I. wire and get earthed, resulting blowing of the fuse.
There are two type of guarding according to the formation.

(A) To use in case of ‘D’ clamps.
(B) Direct shackle type.
Page 71 of 333
2. Lecing guarding.
This has following types. a) Carpet guarding, b) Cradle type c) Box type. There is two, three or four
guard wire for lacing guarding. These are bound with cross arm. The horizontal laces at a specific
distance are tied up to the above wires. This guarding is used up to 33 KV lines
Carpet Guarding: - The specific length cross arms are fixed on the poles. Four G.I. wires are used
for guard wire. Lacings are tied up at specific distance. This type is used for power line crossing or
power and telephone line crossing.
Cradle Guarding: - It consists of 6 guard wire. Four are on lower side and two on the upper side.
Cross lacing is done from three sides. It is also called Tray guarding. Even though the conductor
while snapping jumps up drastically, it will not go out of the cradle guarding. This is used for
railway or L.T. to 33 KV guarding in residential area, for road crossing or along the road lines.
Page 72 of 333
Box type guarding: - This is used for composite lines. By fixing cross arms to the lower line,
carpet guarding is done and also for the upper line, the upper guard wire is fixed to the lower by
vertical lecing.
Road crossing and guarding.
 As far as possible, road crossing should be at right angle, but not less than an angle
of 60 degrees.
 Cradle guarding is used for road crossing of power line or along the line.
 G.I. wire of 10 W.S.G. for L.T. line and 8 W.S.G for 11 KV to 33 KV lines is used
for guarding.
 The first lacing should be at a distance of 750 mm from the pole. Other lecing are
tied at a distance of 3 meter from each other.
 The vertical distance between conductor and guarding in mid span should be
minimum 610 mm for L.T. and 1220 mm for H.T line.
 The vertical distance between L.T. line guarding cross arm and neutral should be
610 mm (2 ft.) and the length of cross arms should be 750 mm (2 ½ ’) .
 The clearance between line and guarding cross arm for 11 KV, 22 KV and 33 KV
line should be 650 mm (2 ¼’), 750 mm (2 ½’) and 840 mm (2 ¾’) respectively.
 There is no need of guarding for lines above 66 KV, as their circuit breakers are
sensitive. The breaker trips when conductor snaps thereby isolating the line.
Page 73 of 333
AT 11 KV LEVEL
DISTRIBUTION TRANSFORMER
Introduction
A transformer is a static piece of equipment with two or more windings, conductively disjointed,
but magnetically coupled by a time varying magnetic field, meant for transferring power from one
voltage level to other. A distribution transformer is one of the main components in a distribution
system network. Major faults in the transformers can cause extensive damage which not only
interrupts electricity supply but also results in large revenue losses. Poor/inadequate maintenance in
the areas of oil leakage, oil quantity, and critical accessories such as tap changers, bushings and
protective instruments is the main reason for transformer failure. With appropriate on site actions
like proper commissioning procedure and maintenance the useful life of the transformer can be
extended.
Scope:
This operational guideline is intended to carry out the fundamental checks on Transformer for its
maintenance and while taking it into service. This requires that the concerned SDO should prepare
the action plan and ensure the availability of necessary tools and tackles to carry out this activity.
Prerequisites:
Ensure that necessary permit has been taken. Feeding Sub-station is responsible for providing
outage and PTW. The working party is responsible for ensuring isolation. Ensure that the
transformer is de-energized, isolated & grounded.
Working party should ensure the availability of proper tools and accessories, safety apparels, spares
and consumables required for carrying out the work.
Checks & Directives:

a) For oil filled Distribution Transformers including mobile Trolley Transformers.
b) For Dry Type Transformers
Page 74 of 333
a) For oil filled Distribution Transformers
S Type of Item Frequency Points to be checked Action to be taken in case of any
No Check anomaly
a) Silica Gel should be blue. a) If not, replace with blue silica gel.
As and when b) If any defect in body/cup, replace it
Physical required/Half b) No crack in body of breather & oil cup. c) If not oil filling to be done in cup up to the
1 condition Breather Yearly c) Oil level in oil cup should be up to the mark mark
2 Physical Oil leakages As and when a) Check for any oil leakage from a) Oil leakage to be attended at site, if not
Condition required/Half transformer tank, radiators, HV-LV possible at site then transformer to be
yearly bushings & any gasket joint etc. sent to work shop.
3 Physical Oil level As and when a) Oil level to be checked in gauge. a) If oil level not up to the mark then oil top
Condition required/Half up to be done immediately with fresh oil.
yearly
4 Physical Palm connector & Yearly a) Check for any arcing/pitting mark on a) If any defect Palm connector & AL bus
Condition AL bus-bar Palm connector & AL bus-bar. B) Check for bar to be replaced separately.
any discoloration due to local heating.
5 Physical HV-LV bushings Yearly a) Check for any crack/flash mark on HV- a) Defective Bushing to be replaced. b)
Condition LV bushings if any. b) Check for dust on Bushing to be cleaned with dry cloths.
HV-LV bushing.
6 Physical Tank body & Yearly a) Check for dust & rust on transformer a) Tank body & radiators to be cleaned. b)
Condition radiators body& radiators. painting is to be done if required.
7 Physical Tank body Yearly a) Tank body should be earthed at two a) If not, tank body earthing to be done at
Condition earthing placed with separate earthing point. two places.
8 Physical Neutral earthing Yearly a) Neutral should be earthed at two placed a) If not, neutral earthing to be done at two
Condition with separate earthing point. places.
9 Physical Arcing horns Yearly a) Check for pair of arcing on each phase of a) If not, then arcing horns to be fitted.
Condition HV bushing. b) Arcing horn alignment to be done.
b) Check for alignment of arcing horn.
10 Electrical Earth resistance Yearly a) Earth resistance should be = <1 Ohm a) If not then check for earthing pit or go
for new earthing
11 Electrical IR Value Yearly a) IR value shall be equal for all three a) If not then recheck the IR values.
phases for HT-E, LT-E, HT-LT. b) If value are lower then the values
b) Normally IR value shall be minimum specified then plan for
100 MΩ for HV & 50 MΩ for LV overhauling/replacement.
windings at the temp of 50°C. c) If IR value decreased more than
c) Compare previous & present IR 20% then need to investigate.
value.
12 Electrical Oil BDV Yearly a) BDV of transformer oil have to be greater a) If oil BDV is less then 30KV then plan
than 30 kV (avg) at 2.5mm gap. for overhauling/replacement.
13 Mechanical HV-LV termination Yearly a) Check for intactness of HV-LV a) If not tightening HV-LV nut-bolt and
termination, cleating for LV leads & HV accessories to be done.
cable. b) Tension on HV-LV terminals due to
b) Check for any tension on HV-LV cable/ conductor to be rectified.
terminals due to cable/ conductor.
14 Mechanical Vibration in As and when a) Check for any abnormal sound from a) If abnormal sound observed then keep
transformer required/yearly transformer. There should be a healthy Watch/plan for overhauling/replacement.
humming sound.
15 Electrical Thermoscanning As and when a) Check for thermo scanning half yearly/ a) Take corrective action if hot spot and
required/Half before and after of planned maintenance other abnormality detected.
yearly during pre and post maintenance visit.
16 Electrical Oil Every five year a) In addition to Oil BDV given additional a) If results are not with in limit then
of service test to be conducted on oil every five years transformer to be sent for overhauling at
of service; Water content<35PPM, Tan work shop.
delta<0.5, Resistivity>1.0X10^11ohm-cm,
Acidity<0.15mg KOH/g, Sludge-0% by wt,
and Flash point>125
Page 75 of 333
(i) Note: For Mobile Trolley Transformers including above checks following additional checks
to be conducted:
SL Type of Item Frequency Points to be checked Action to be taken in case of any

no Check anomaly
1 Physical Trolley As and when a) Check for physical condition of trolley. a) If damaged then plan for rectification.
Condition required/Half
yearly
2 Physical Tyre As and when a) check for condition of tyres. a) If damaged then plan for rectification.
Condition required/Half b) Check for air pressure in tyre. b) If not ok then plan for filling of air.
yearly
3 Physical Earthing As and when a) Check for earthing between transformer a) If not ok then rectification to be done.
Condition required/Half to earthing point provided on trolley.
yearly
Minimum/Maximum required
S. No Type of test Test Significance Frequency
Values
Electrical BDV Poor oil BDV shows ingress of moisture, dust Yearly >30 KV
and carbon particles
1
Chemical Water Content Water(Moisture) will dissolve in insulating oil 5yearly/as and <35 PPM
and will contribute a hazard not only to the di when required
electric performance of the oil itself but also to
the solid insulation immersed in oil
2
Chemical Tan Delta It is a good value to indicate the quality of 5yearly/as and <0.5
Insulation. High value of DDF indicates the when required
presence of contaminants, deterioration products
such as water , Oxidation products, metal
Soaps, soluble varnishes and resins.
3
Chemical Flash point It is the minimum temperature at which heated 5yearly/as and >125
oil gives off sufficient vapour to form a flammable when required
mixture with air
4
Chemical Resistivity It is the resistance between the opposite 5yearly/as and >1x10^11ohm-cm
phases of a centimeter cube of the liquid. IR of when required
the windings in a transformer depends on the
resistivity of the oil also. Low resistivity
indicates the presence of moisture and or
Conductive contaminants in Oil.
6
Chemical Sludge content sludge is oil deterioration products or 5yearly/as and 0% by weight
contaminates, or both which are insoluble in oil when required
7
Chemical Acidity measure of free organic and inorganic acids 5yearly/as and <0.15mg of KOH/g
present together in the oil when required
8
Page 76 of 333
Significance of tests & frequency of transformer oil & required value:
b).For Dry Type Transformers
SL Type of Item Frequency Points to be checked Action to be taken in case of any

no Check anomaly
1 Physical HV-LV bushings Yearly a) Check for any crack/flash mark on HV- a) Defective Bushing to be replaced.
Condition LV bushings if any. b) Bushing to be cleaned with dry cloths.
b) Check for dust on HV-LV bushing.
2 Physical Enclosure, Doors, Yearly a) Check for dust & rust on enclosure & HV- a) Enclosure & HV-LV cable box to be
Condition marshalling Box LV cable box. cleaned.
3 Physical Enclosure doors Yearly a) Check for doors are properly closed or a) Ensure all doors shall be properly
Condition & marshalling box not. closed.
Door b) There should not be any open space at b) Any open space/gap to be filled with
cable (HV & LV) inlet &earthing strip. insulating material.
4 Physical Marshalling box Yearly a) check for working/setting for thermo stat. a) Proper setting to be done if required.
Condition b) check for working and physical condition b) Energy meter should be in working
of energy meter. condition.
c) Check for working for lamp. c) Lamp should be switched off when door
is closed.
5 Physical Active part Yearly Check for dust deposition over core coil Dust cleaning to be done with the help of
Condition assembly of transformer. air blower if required.
6 Physical Enclosure Yearly a) Enclosure should be earthed at two a) If not, tank body earthing to be done at
Condition earthing placed with separate earthing point. two places.
7 Physical Neutalearthing Yearly a) Neutral should be earthed at two placed a) If not, neutral earthing to be done at two
Condition with separate earthing point. places.
a) If not, then check for earthing pit or go
8 Electrical Earth resistance Yearly a) Earth resistance should be = <1 Ohm for new earthing
9 Electrical IR Value Yearly a) IR value shall be equal for all three a) If not then recheck the IR values.
phases for HT-E, LT-E, HT-LT. b) If value are lower than the values
b) Normally IR value shall be minimum specified then plan for
100 MΩ for HV & 50 MΩ for LV overhauling/replacement.
windings at the temp of 50°C.
10 Mechanical HV-LV termination Yearly a) Check for intactness of HV-LV a) If not tightening, HV-LV nut-bolt and
termination. accessories to be done.
b) Check for any tension on HV-LV b) Tension on HV-LV terminals due to
terminals due to cable. cable to be rectified.
11 Mechanical Vibration in As and when a) Check for any abnormal sound from a) If abnormal sound observed then keep
transformer required/yearly transformer. There should be a healthy Watch/plan for overhauling/replacement.
humming sound.
12 Electrical Thermoscanning As and when a) Check for thermo scanning half yearly/ a) Take corrective action if hot spot and
required/Half before and after of planned maintenance other abnormality detected.
yearly during pre and post maintenance visit.
13 Electrical Exhaust fan As and when a) Check for working of exhaust fan. a) Ensure for working of exhaust fan.
required/Half
yearly
Authorization
The SDOs will ensure that the operational directives and guidelines are followed at every level. The
compliance report provided as Annexure is to be duly signed by JE and counter signed by SDO and
Page 77 of 333
the same has to be kept as record. The record may be available with respective SDO / JE should be
presented for verification during the audits.
Implementation
The SDO shall be responsible for implementing these operational guidelines while commissioning
of Transformer. Detailed record of the activity has to be maintained separately.
Review:
The Executive Engineer will be responsible for reviewing this directive every two years or as
necessary in accordance with the revised standards (IS & IEC) and also from learnings observed
during the commissioning activities.
FORMATS/ ANNEXURE –DT-1 TO DT-7 ATTACHED
Page 78 of 333
RING MAIN UNIT (RMU)
Introduction:
Ring Main Unit (RMU) is used to make a ring system in electrical network to provide the reliable
supply to the people we served. RMU is very compact as compared to old type Oil & Air Circuit
Breakers. The chamber of RMU is filled with Sulphurhexafluoride (SF6) gas for insulating purpose.
This system change is taking place worldwide, since each of previously used insulating and arc-
quenching media, such as air and oil, have their own more or less serious disadvantages:
Air-insulated systems take up a great deal of space and, in extreme climatic or environmental
conditions, require maintenance.
Oil-insulated systems although on the whole well protected against external influences, pose a
considerable safety risk in the event of an internal fault.
Scope:
This operational guideline is intended to carry out the fundamental checks on RMU for its
maintenance and while taking it into service. This requires that the concerned engineer should
prepare the action plan and ensure the availability of necessary tools and tackles to carry out this
activity.
Prerequisites:
Ensure that necessary permit has been taken. Feeding Sub-station is responsible for providing
outage and PTW. The working party is responsible for ensuring isolation. Ensure that the Cable is
de-energized, isolated & grounded.
Working party should ensure the availability of proper tools and accessories, safety apparels, spares
and consumables required for carrying out the work.
Directives & Checks:
S.No. Description Range/Value/Status
Should be in Green zone. If found in Red zone

1 Manometer (SF6 Gas Pressure)
then do not operate.
FPI can be checked through test button

Functioning of FPI(Fault passage mounted on the same. VPIS can be checked
2 Indicator) and VPIS(Voltage Presence through LEDs. All LEDs should blink when
Indication System) the cable is charged. If found defective,
intimate to M&P
Page 79 of 333
When LBS/OFF Load Switch is in closed

Interlocking between LBS/OFF Load
position, earth switch of the same should not
3 Switch (in case of Vacuum Breaker)
be closed and vice-versa. If found defective,
and Earth Switch
intimate to M&P
a) When Breaker is in closed position, OFF

Load Switch should not operate whether the
Interlocking between Switch is in closed position or in Open
position.
a) Breaker and OFF Load Switch (in
case of Vacuum breaker).
b) When Breaker is in closed position, earth
4
b) Breaker and Earth Switch (in case switch of the same should not be closed and
SF6 Breaker) vice-versa.
c) Earth Switch and Cable door c) When the Earth Switch is in closed position
then only cable door can be open and vice-
versa.
Earth connections should be properly

5 Earth Connections and earth resistance tightened and earth resistance should be
<1ohm.
a) Cable should be tightened with Box spanner

set/Ratchet Socket set and bi-metallic washer
should be used between cable bushing and
a) Cable tightness cable lugs.
6 b) Cable cleat/support b) All cables should be supported with cable

c) Cable Entry Point cleat and all cable cleats should be properly
tightened.
c) All cable entry points should be closed

properly to prevent entry of lizard/rat etc.
Page 80 of 333
Tests:
1 IR Test Should be >5Gega Ohm
2 Earth Resistance Should be <1 ohm
3 Contact Resistance Should be <300 micro ohm
Should be withstand for 1 minute on 18kV and for

4 Hi Pot Test
subsequent 80% of the previous test voltage.
5 Relay testing and tripping circuit Should be healthy.
* Note:– All Tests to be carried once in a year with the help of Metering & protection department.
4-way Schneider RMU
Page 81 of 333
Single Line Diagram of RMU Connectivity
4-Way RMU 3-Way RMU
Load Break
Circuit Switch
Breaker
Distribution Line / feeder Distribution

Transformer Transformer
Maintenance Activity:
General Maintenance
 Ensure that there is no gas leakage in the RMU by checking manometer

 RMU to be isolated after obtaining PTW no. from the Feeding Sub-station.
 Ensure that incoming supply is switched OFF by physical verification of the upstream
Breaker/Isolator/Grid. Also ensure that Voltage presence Indicating system - LED’s
should not blink in the RMU.
 Open the Circuit Breaker and Isolator.
 Close the earth switch.
 Open the cable door and check the tightness of cables. Ensure proper grounding of the
cables and the RMU structure.
 Ensure proper connection of the Earthing strip, Fault Passage Indicator(FPI) and
associated CT’s.
 Open the front covers and clean all the breaker and isolator mechanism.
 Use blowers to remove dust on the control mechanism.
Break down Activity
 Ensure that there is no gas leakage in the RMU by checking manometer.
Page 82 of 333
 RMU to be isolated after obtaining PTW no. from the Feeding Sub-station.
 Ensure that incoming supply is switched OFF by physical verification of the upstream
Breaker/Isolator/Grid. Also ensure that Voltage presence Indicating system - LED’s
should not blink in the RMU.
 Open the Circuit Breaker and Isolator.
 Close the earth switch.
Authorization
compliance report provided as Annexure is to be duly signed by Junior Engineer and counter signed
by SDO and the same has to be kept as record. The record may be available with respective SDO /
JE and should be presented for verification during the audits.
Implementation
The JUNIOR ENGINEER shall be responsible for implementing these operational guidelines while
commissioning of RMU. Detailed record of the activity has to be maintained separately.
Review:
The XEN will be responsible for reviewing this directive every two years or as necessary in
accordance with the revised standards (IS & IEC) and also from learnings gained during the
commissioning activities.
CHECK LIST/ ANNEXURE- RMU-1& RMU- 2
Page 83 of 333
UNDERGROUND CABLES
Introduction
The underground cable network of any electricity distribution utility is a vital component of the
LV/HV network of the system. It has a several unique benefits over overhead networks. In
particular, they have:
 Lower transmission losses.

 Can absorb emergency power loads.
 Have lower maintenance costs.
 Emit no electric field and can be engineered to emit a lower magnetic field than an
overhead line;
 Require a narrower band of land to install.
 They are less susceptible to the impacts of severe weather.
The reliability of the underground distribution network directly affects the reliability of the overall
system and ultimately the overall customer satisfaction.
Scope
The operational guidelines apply to DHBVN engineers & any of Business Associates involved in
Testing & Repairing of Cable faults being carrying out for maintenance of electricity distribution
system.
Prerequisites
 Ensure that necessary permit has been taken. Sub-Divisions & Systems are responsible
for ensuring isolation of the faulty cable for both ends & providing the PTW. Ensure that
the cable is de-energized, isolated & grounded.
 The Business Associates should ensure the availability of proper tools and accessories,
safety apparels, spares and consumables required for carrying out the work.
Page 84 of 333
Directives & Checks
Preventive-Corrective
Abnormality Causes/ Effect
action plan
1. Flash over due to Phase to phase &

Phase to earth clearance at cable Ensure sufficient clearance
termination
2. Termination failure due to Core Ensure core crossing below cut
crossing above cut back area at cable back area at cable termination
Electrical
termination
Stress
3. Termination failure due to
Contaminated surface of Ensure cleanliness of terminations
terminations
Ensure Testing at Recommended
4. Cable failure due to Cable testing at
Voltage
high voltage(DC)
(Refer table2)
1. Stress develop due to Improper Ensure Proper Bending radius
Bending Radius (Refer table1)
Mechanical
2. Stress develop due to Mechanical Ensure proper depth
Stress vibrations (Refer table3)
3. Stress develop due to Improper cable Ensure proper span length
supports
1. Insulation degradation dueto Ensure Recommended Loading
overloading (Refer table4)
Ensure proper
Thermal 2. Insulation degradation due to Hot Tightening/crimping of Lugs &
Stress spot at joints & Terminations Ferrules
Ensure Cable earthing connected

3. Insulation degradation due to
Improper Earthing connections with Sub-stationearthing
External
Insulation Damaged by external agency Ensure Patrolling of cable routes
damage
Leakage current through the cable

insulation/ cable failure, Corrosion in Ensure Lug seal to be intact at
Water ingress
cable conductor &Armour due ingress outdoor termination.
of water
Page 85 of 333
Minimum permissible Bending radius (Table1)
PILC XLPE
1C 3C 1C 3C
Upto 1.1 KV 20D 15D 15D 12D
1.1 KV to 11 KV 20D 15D 15D 15D
Above 11 KV 25D 20D 20D 15D
‘D’ Diameter of the cable

Table 2: Tests on Cable during Fault Localization, After Repair or when Network Modification is
done.
S. No Test UG Cable
Phase to Ground and Phase to Phase to be tested
with 2.5/5.0 KVmeggar for one minute or
till reading stabilized. Minimum IR value
1 Meggar
should be 50 M ohms.
Each phase to be tested @ 6.5 KV DC

for 5 minute with respect to ground with
2 Hi pot other two phases grounded. The cable
must with stand the test voltage &
leakage current should not exceed 2mA
Page 86 of 333
Depth of the cable (Table-3)
Voltage Level Depth of cable
LT cable (1.1kv) 0.6 m
HV cable (11kv) 0.9 m
EHV cable (33kv) 1.2 m
EHV cable (66kv) 1.5 m
Current Rating (Table4)- 11 KV XLPE UG Cable
Current Carrying Capacity (Amps)

Nominal Size of
S. No. Cable (Sqmm)
for 11 kV level
In Ground at 30˚C In Duct at 30˚C In Air at 30˚C
1 3x95 190 165 230
2 3x120 220 190 260
3 3x150 245 210 295
4 3x185 275 240 335
Page 87 of 333
Current Carrying Capacity (Amps)
Nominal Size of
S. No. Cable (Sqmm)
for 11 kV level
In Ground at 30˚C In Duct at 30˚C In Air at 30˚C
5 3x240 315 275 395
6 3x300 355 310 450
7 1x630 560 480 840
8 1x1000 680 580 1070
Authorization
compliance report provided as Annexure is to be duly signed by JUNIOR ENGINEERand counter
signed by SDO and the same has to be kept as record. The record may be available with respective
SDO & JUNIOR ENGINEER and should be presented for verification during the audits.
Implementation
The SDO shall be responsible for implementing these operational guidelines while Cable testing &
Repairing.
Review:
necessary in accordance with the revised standards (IS & IEC)
CHECK LIST/ ANNEXURE- UG-1 ATTACHED
Page 88 of 333
HT OVERHEAD LINES
Introduction:
Overhead lines are the most cost effective and frequently used carriers for electric energy. Exposure
to environment accelerates deterioration; if this not detected and repaired quickly, some of it will
degenerate into serious problems with time. To increase line loading and increase quality of power
supply, frequent inspection programs is required to locate and repair any significant failure at the
earliest possible stage.
Frequent failure in the Overhead lines can cause extensive damage to the insulator and other
electrical & earth joints which not only interrupts electricity supply but also results in large revenue
losses. Poor/inadequate maintenance in the areas of pole, span length, non-tension electrical joints,
conductor spacing, line stay leads to the instability in the electrical and mechanical parameter which
reduce the life of the line. With appropriate on site actions, like proper maintenance procedure, the
useful life of the overhead lines can be extended.
Scope:
This operational guideline is intended to carry out the fundamental Line Survey / Checks for its
prepare the action plan and ensure the availability of required materials, tools and tackles to carry
out this activity.
Prerequisites:
Ensure that necessary permit has been taken from feeding sub-station officer who is responsible for
providing outage and PTW.
The Operating personnel is responsible for ensuring de-energization, isolation and properly
grounding the network where the activity has to be carried out.
Properly Grounding means

 All conductor of the isolated working zones, should be shorted with earth by shorting
links at both ends.
 The end of the shorting links which are to be connected with conductor & earth terminal
should be fitted with crocodile clip. (Presently all conductor are shorted with safety
chain without earth.A thin layer of Aluminium oxide form on conductor as it expose in
air which behaves like insulator. Due to small surface contact area by the safety chain
&conductor may cause high resistance at the chain contact point causing unusual
behavior. Shorting links should Better performance than safety chain)
 If there be any branch line within the working zones, should be isolated/all conductor to
be shorted in similar manner.
Page 89 of 333
 If there be any DT within the working zones, the G.O (Gang Operated Switch) of all
DT’s should be OFF to avoid any back feeding from downstream.
 During fixing the crocodile clip of shorting links to the conductor, it should be careful :
 Before connection the shorting clip to the conductor, the earthing terminal of
the shorting clip should be earth.
 Before connecting the shorting clip to a conductor, it (conductor) should be
earth by earth stick & holding the earth stick on the said conductor, the
crocodile clip of shorting links should be fastened with the conductor by
wearing safety gloves & then the earth stick to be removed. Repetition of the
same process of other too conductors must also be ensured.
The Working personnel should ensure the availability of proper tools and accessories, safety
apparels, spares and consumables required for carrying out the work.
Clearance
LV 11 KV
Minimum clearances from any accessible point
The vertical clearance from the highest
2.5 m 3.7 m
point
The horizontal clearance from the
1.2 m 1.2 m
nearest point
Minimum Ground Clearance
Across the street 5.8 m 6.1 m
Along the street 5.5 m 5.8 m
Line erected elsewhere 4.6m 4.6m
Line with Insulated Conductor 4m 4m
Line crossing 11 KV & LT line 2.4m
Current carrying capacity of conductor
Current currying capacity in

Size of conductor
Amp
Dog (100 sqmm/ 1 SWG) 312
Raccoon (80 sqmm/3 SWG) 297
Rabbit ( 50 sqmm/ 6SWG) 247
Weasel (30 sqmm/ 8 SWG) 114
Page 90 of 333
Checks & Directives: For 11 KV O/H Feeders
1 Line Support a) Depth of the Pit should be1/6 of the
a) Pole - 11m pole size.
b) Stay b) Pit filling concrete ratio 1:3:6
c) BasePlate-450mm×450mm×75mm c) Pole should be straight & to be
i. GI wire-7/10 SWG erected as per drawing of DHBVN.
ii. Guy/Egg Insulator/Stay insulator d) Stay angle should be min.30°
iii. Tension screw max 45°& should be fix at every pole
iv. Anchor hook where the line has deviated by more
v. Stay collar than 5°,End poles & Branch out/tee off
vi. Thimble pole. It would erect as per DHBVN
d) Strut Pole guidelines.
e) Strut pole & flying stay should
be erect at the place where no provision
for stay has.
 Strut pole pit shall be located at
a distance not less then 1.8m
from the pole.
 The depth of pit shall be such
that at least 1.2 m of the strut is
buried in the ground.
f) Tension screw, Stay collar,
Anchor hook and all hardware fixing,
Nuts& bolts to be checked.
g) Egg insulators to be provided in
all stay wire to prevent electrocution of
animal / human being during rainy
season.
2 Line Hardware : All line Hardware should havesuitable
a) Strain Insulator (Disc insulator) mechanical load bearing strength
b) Strain Clamp &capacity to avoid any breakage.
c) Pin Insulator
d) Spindle
e) Top Hamper
f) V –arm
g) Channel arm
Page 91 of 333
Tests
S. No. Description Range/Value/Status
1 Earth Resistance
a) Individual earth Should be <1 ohm
b) Continuous earth Should be < 5 ohm

PI value (ratio of IR values at 600 sec to
2 60 sec) only OH lines excluding Txs Should be > 1.25
,cable etc
3 IR value Should be> 100 MΏ
Suitable as per loading of the
4 feeder & to be thoroughly
Bare Conductor
checked for any damage/cut
mark on the conductor.
It should be depend on the
size of the conductor/ABC
cable and pole height/type to
maintain min. Sag &
specified ground clearance
Span Length
It would be 40 m& 50 m for
PCC pole for Urban area &
5 Rural area respectively.
Sag of HT line to be
tightened, if found loose.
Spacers to be provided
especially where span
length of lines is more.
6 Section of Line Should be of 4/5 span

Earth connections should be
properly tightened with all the
metal part and guard wire. If
any Joints have observed in
7 the running portion of GI
Earthing and earth resistance
wire, should be removed.
Earthing should be done
every 5 pole apart & earth
electrode should go up to
water level. Earth Resistance
Page 92 of 333
value should be <1ohm.

Should be erected by 4 SWG
GI wire, the guard should 4-5
8 Guard wire per span for along the road &
it would 8-10 per span for
crossing the road.
9 Joints
Conductor should be joint by
a. Mid span joints means of sleeves as per
conductor size.
a) Jumper should be of same
conductor as of I/C cable or
next higher size rating.
Jumper jointing shall be made
using C-wedge connector/ PG
b. Jumper joints
Clamp/D Clamp.
b) If jumper length > 1m
then it should be supported
after installation of Pin
Insulator.
Should be fixed on conductor
10 Poly- pro insulation both side of Line insulator to
avoid birdage.
11 Should be fixed on pole
Anti-climbing device
structure
12 All metal part should be paint
Painting & Pole Numbering
& pole has to be numbered.
13 Danger plate should be fixed
Danger plate
at All pole
Cable cleat & cable
14 supporting pipe should be
UG Cable cleat, cable supporting pipe
provided, at the pole where
cable has terminated.
Feeder identification has to be
done in case there is more
15 Feeder Marking than one circuit on the same
pole. Identification tag should
be fixed on alternate pole.
Proper Plinth/Muffing should
16 Pole base plinth/ muffing be done on every pole as per
the site condition.
* Note: – Earth resistance tests to be carried out once in a year
Page 93 of 333
Maintenance Activity:
General Maintenance
Check visually, the condition of Pole base & alignment of pole. If the pole tilted, should be
straighten & rammed the pole base with brick bats after digging the earth around the pole base. If
any bend occurred at the mid of the pole, has to be changed & pole to be erected as per drawing
attached.
Check visually the condition of existing stay
 Check the Condition & size of GI wire. It should be 7/10 SWG.
 Check the Condition of Guy/Egg Insulator, if any damage or missing observed, should
be fix/replace.
 Check the Condition of tension screw, if any damage observed , it has to be changed
otherwise to tighten the turn buckle ,if required
 Check the condition of anchor hook
Check visually the Line Hardware
 Condition of Disc Insulator, if there is any crack, flash mark on the surface of the disc,
disc should to be change.
 Condition of strain clamp of disc insulator, If any crack or flash mark on surface, it has
to be change.
 Condition of Pin insulator, if there be any flash mark on the insulator surface, it has to
be change otherwise check the tightness with the spindle.
 Condition of Pin insulator spindle, if any damage or bend, to be change otherwise check
the tightness of the fixing nuts.
 Condition of Top hamper; if any tilt observed at top hamper, it has to be straight or any
damage occurred to the metal part, it is to be change, otherwise check the tightness of
fixing nuts bolts.
 Condition of the V-arm. if any damage occurred on V-arm or on the fixing clamp, it is
to be changed otherwise check the tightness of the fixing Nuts, bolts
 Condition of channel-arm, if any damage occurred on channel-arm or on the fixing
clamp, it is to be changed otherwise check the tightness of the fixing Nuts, bolts.
 All metal part to be painted by Primer &Aluminium paint for increasing the durability of
life span. Further all metal parts on the pole of line should be connected to proper earth.
 Visual inspection of bare conductor -if any damage occurred on the conductor, it is to be
replaced the damaged portion by same conductor with sleeve joint & the joint is limited
to maximum 2 nos.per span. If any loose, conductor to be re-sagged from section to
section. Also maintain spacing between the conductors.,
 Span length should be maximum 40 meter for urban & rural residential area & 60 meter
for rural field area if the length larger than above so mid pole to be provided.
 Line should be sectioned at every 4/5 span apart.
Page 94 of 333
Inspection of Joints
 All jumpers should be made by conductor of same as line conductor or by the next
higher size rating conductor & joints to be made by suitable C-wedge connector. Mid
span joint to be done by Suitable Sleeves & the joint is limited to 2 no. per span.
Anti-climbing device
 It is installed around the pole to prevent unauthorized persons from climbing the
structure .Anti-climbing to be fixed on every pole where cable mounting as OH feeder.
Cable being taken up to top of line and jumper at cable end should be made through
properly crimped lugs and fitted with C-wedge connector with line.
Trimming of Tree-branches
 To have proper clearance from HT line should be ensure in order to prevent from
transient faults.
Authorization
The SDOs will ensure that the operational directives and guidelines are followed at every level.
The survey report is to be duly signed by JUNIOR ENGINEER/project engineer and counter
signed by SDO and the same has to be kept as record. The record may be available with
respective SDO & JUNIOR ENGINEER and should be presented for verification during the
audit.
Implementation
The JUNIOR ENGINEER shall be responsible for implementing these operational guidelines
while execution of maintenance activity. Detailed record of the activity has to be maintained in
the System.
Review:
necessary in accordance with the revised standards (IS & IEC) and also from learnings gained
during the commissioning activities.
Page 95 of 333
Components of an Overhead 11 KV (H.T.) Line of O/H
Lines
1. Reinforced cement concrete poles (R.C.C. Poles)

2. Double pole structure
3. Cross – arms
4. Line conductors
5. Pin-type insulators
6. Strain insulators
7. Earth wires
8. Angle iron for earth wire
9. Hooks for earth wire
10. Top hamper
11. Stay wire
12. Stay insulators
13. Anchor rod
14. Dead end clamps
15. Parallel grooved clamp (P.G. Clamp)
16. Earthing
17. Lightning arrestors
18. Danger plates
19. Anti –climbing device
20. Tie wire
Page 96 of 333
Page 97 of 333
CHECKLIST –Annexure-OH-1 Attached
DRAWING (STAY)
X Y Z
LINE For For For For

A B D Bare AB Stay Stay Stay Stay
TYPE
Conductor Cable Angle Angle Angle Angle
45° 30° 45° 30°
HT 9200 1800 65 875 400 1400 1700 1400 1000
LT 7500 1500 50 400 400 1400 1700 1400 1000
All dimensions in mm
Page 98 of 333
Total 49 Nos of Rounds (7x7 Nos)
Step wise winding
Total 49 Nos of Rounds (7x7 Nos)

Step wise winding
Page 99 of 333
Page 100 of 333
HT AERIAL BUNCHED CABLE
Introduction
The AB cable network of any electricity distribution utility is a vital component of the HV
network of the system. The reliability of the AB cable distribution network directly affects the
reliability of the overall system and ultimately the overall customer satisfaction.
Scope
The operational guidelines apply to DHBVN& any of Business Associates involved in Testing
& Repairing of Cable faults being carrying out for maintenance of electricity distribution
system.
Prerequisites
 Ensure that necessary permit has been taken. Sub-divisions are responsible for ensuring
isolation of the faulty cable for both ends & providing the PTW. Ensure that the cable is
 Patrolling of AB cable feeder may be conducted to identify & removal of unauthorized
tappings before starting of the work.
 Copper Screen of HT ABC must be shorted along with messenger wire at starting & End
points and joints with crocodile clamp shorting’s. So that all conductive paths may be
kept at zero potential/ Earth potential
 AB cable joints should be made properly. AB cable should not be jointed temporarily. In
case of emergency, proper joints must be made the next day. For jointing of Messenger
wire, mid span joint sleeve should be used instead of binding wires.
Page 101 of 333

 The Business Associates should ensure the availability of proper tools and accessories,
Laying of AB Cables
It may be ensure that AB cable should not be dragged on roads/ footpaths etc. It must be laid by
use of rollers & pulleys. In case AB cable is laid through trees/ vegetation area, branches may
be trimmed to avoid abrasion on AB cables.
Characteristics of HT ABC
Symptoms prior to failure
At initial stage:
In Majority of cases, sparking & hissing sound is developed between Copper screen &
Messenger wire of HT ABC because of improper connection between copper screen &
Messenger wire.
Later stage:
Outer Sheath burnt along the Messenger wire & damage of XLPE insulation due to heat of
sparking.
Sparking spot
Page 102 of 333

Outer sheath burnt
Insulation damage due to sparking
Reason of Failure:
Design Snags-
 Induction of high voltage at copper screen.

 Under rated fault withstand capacity of Cu screen.
 Manufacturing defects
Installation snags -
 Improper connection between Cu screen & Messenger

 Mechanical damage during installation.
Page 103 of 333

Correctives Measures for Design snags:
 HT ABC with revised specs. (AL wire screen)
nHT ABC instead CU scre
Conventional HT ABC with New HT ABC with Al wire

copper tape screen for 0.25KA screen for 5/ 10KA for one sec
for one sec fault current rating fault current rating
Conventional HT ABC with New HT ABC with Al wire

copper tape
Correctives screen for
Measures for Installation
0.25KA snags: screen for 5/ 10KA for one sec
for one sec
In Existing fault currentABC:
/ Conventional rating fault current rating
To connect copper screens to the messenger wire with at least 25 sqmm single core PVC
unarmored cable at both ends of the HT AB Cable section.
In New Design ABC:
To connect Aluminum screens to the messenger wire with 2run of 50 sqmm single core PVC
unarmored cable at one side of HT AB cable section
Page 104 of 333

Metallic screens connected to messenger wire with PVC single
core AL 2X50sqmm cable for newly laid ABC 10 KA rating.
Metallic screens connected to messenger wire with PVC single

core AL 2X50sqmm cable for newly laid ABC 10 KA rating.
Page 105 of 333

Metallic /copper screens connected to messenger wire with PVC single
core AL 25 mm2 cable
DON’TS
Metallic /copper
Temporary screens
joints must beconnected to emergency
restricted. In messenger wire
case, with
while PVCtemporary
making single joint,
corecopper
AL 25screen
sqmm cable
continuity must be maintained. Standard joint must be installed at the
earliest possible.
 Copper screens connected to messenger wire with fuse/ conductor strand wire.
Page 106 of 333

Comparison: (Existing/Conventional HT ABC Vs. Revised HTABC)
Revised HT
S. No. Particulars Existing HT ABC Remarks
ABC
1 Outer Sheath HDPE PVC NA
2 Moisture Barrier Tape Not provided Provided NA
3 Metallic Screen Cu tape Aluminum wire NA
Fault with stand capacity

4 0.250 KA 10KA NA
of metallic screen
Measurements on Metallic screen in Service Condition
Potential on metallic
1 screen w.r.t. earth @ no 4.49 KV Negligible NA
Load condition
Single end screen

bonding with
Circulating current in
messenger wire is
metallic screen when 30% of the
2 negligible recommended to
both ends bonded with cable load
prevent circulating
messenger @ 100A
current in 5 KA &
10KA design.
Typical Failure of HT AB cable

Some of the typical failures of Aerial Bunched Cables are follows:
 Crack on the outer surface of the AB cable:
 The outer most sheath is PE or PVC .Since the outer sheath is subjected to UV rays,
the outer sheath cracks & the metallic screen i.e. Copper screen is exposed to
moisture which oxidizes. In case of fault, the fault current would over heat the
location of high resistance of the metallic screen which damages the XLPE
insulation and causing total damages to HT ABC.
 Copper Metallic Screen Damage:
 To enhance the reliability of HT ABC, the cross sectional area of metallic screen
needs to be increased. The area of metallic screen is given by
Page 107 of 333

A= π x dm x b
Where A= Cross Sectional area of metallic screen in sqmm.

dm= Mean diameter of the metallic screen in mm
b = Nominal thickness of metallic screen in mm
in the above formula the mean diameter of the metallic screen varies with the
conductor cross sectional area.
 Burnt Outer Sheath:
 Burning of outer sheath due to improper earthing.
 Damage of outer sheath due to animal bites:
 The outer sheath of HT ABC emits a fruity like smell in case of PE outer sheath
which attracts animals such as rodents or squirrel .Due to this, the rodent & squirrels
normally chew the outer sheath of HT ABC causing further exposure of the metallic
screen in addition to the cracking of the outer sheath due to UV radiation. This
oxidizes the copper screen .This enhances the resistance of the copper screen, thus
causing increase in I²R losses when the screen carries the fault current during short
circuit condition or when the cable insulation punctures due to an incipient defect in
the bulk of the insulation .This leads to the total damage of HT ABC.
 Dislodges Straight through Joint:
 The straight through joint should be as far as possible installed on the pole so
that there is no pulling force exerted on to the outer sheath of the cable or on
the outer tubing of the cable joint. During the jointing of the cables at initial
stage, the cable drum length may be planned in such a way that the joints falls
right at the location of pole. The conductor’s joints are done by using ferrules.
It is important to use a long barrel ferrule .If the short barrel ferrule is used, the
number of crimps that can be done is limited to four, depending upon the type
of crimping tool used and the conductor size.
Condition Monitoring of Aerial Bunched Cables:

Some of the simple tests that can be followed to check the healthiness of the existing Aerial
Bunched Cables network system are as follows:
 Conductor Resistance:
 Both the ends of ABC circuits are to be disconnected at the termination end. At
one of the ABC circuit, the phase conductors are to be shorted by known values
Page 108 of 333

of resistance .The conductor resistance measurement is carried out at the other
end by suitable micro-ohm meter. This test also gives effectiveness of joint both
at the straight through joint and at the termination.
 Metallic screen Resistance:
 The integrity of metallic screen decides the system reliability, when a fault in
the ABC takes place .Unless the resistance is low, the fault current will not be
able to traverse to the earth to trip the system.
 Insulation Resistance:
 The test is carried out at the time of ABC installation and when scheduled
maintenance is taken up or whenever there is a problem in a ABC network. It
is a general assumption that if the Insulation Resistance (IR) is low, it is taken
for granted that the cable is defective .A simple approach can be followed
during maintenance work and by measuring the insulation resistance and
calculating the value of volume resistivity will give a good approach. This will
give a trend analysis of the ABC deterioration.
 Capacitance:
 The individual’s cores can be checked for the capacitance values for the HT ABC
both during the installation and during the maintenance schedule .Even the
individual cable drums can be measured for capacitance before laying or making a
joint. A typical capacitance value of a 95sqmm 11kv XLPE cable is about
0.3µF/km.
Directives & Checks
action plan
Flash over due to Phase to phase & Phase to
Ensure sufficient clearance
earth clearance at cable termination
Electrical Stress HT ABC /Termination failure due to Ensure 1ɸ AL. conductor PVC
improper connection between Earth braid at insulated unarmoured cable with
End termination & Messenger wire. thimble is used for connection
between Earth Braids &Messenger
Page 109 of 333

action plan
wire.
In existing design i.e. with copper
tape screen, 1Run X 25 sqmm
cable may be used at every
termination.
In New design i.e. with AL wire
screen, 2Run X 50 sq mm cable
may be used at the alternate
termination.
Termination failure due to Contaminated
Ensure cleanliness of terminations
surface of terminations
Cable failure due to Cable testing at high Ensure Testing at Recommended
voltage(DC) Voltage (Refer table2)
Stress develop due to Improper Bending Ensure Proper Bending radius
Radius (Refer table1)
Stress/ Abrasion develop due to improper
Mechanical Stress Ensure proper clearance between
clearance between poles & AB cable
poles & ABC
suspended on suspension clamps
Stress develop due to Improper Span length Ensure proper span length
Ensure Recommended Loading
Insulation degradation due to overloading
(Refer table3)
Ensure proper
Insulation degradation due to Hot spot at
Thermal stress Tightening/crimping of Lugs &
joints & Terminations
Ferrules
Ensure ABC & Messenger
Insulation degradation due to Improper
earthing connected to Earth/
Earthing connections
Ground
Insulation Damaged during installation due Ensure use of Rollers/ Pulleys
External damage
to improper Laying practices. during installations.
Ensure Lug seal to be intact at
Water ingress Insulation/cable failure, Corrosion in cable
outdoor termination.
conductor &Armour due ingress of water
Page 110 of 333

Minimum permissible Bending radius
Rating ABC
1C 3C
Upto 1.1 KV 15D 12D
1.1 KV to 11 KV 15D 15D
‘D’ Overall Diameter of the AB Cable
Testing of AB cables:
S. No Test HT ABC
Phase to Ground and Phase to Phase to be tested with 2.5/5.0

1 Meggar KVmeggar for one minute or till reading stabilized.
Minimum IR value should be 50 M ohms.
Each phase to be tested @ 6.5 KV DC for 5 minute

with respect to ground with other two phases grounded.
2 Hi pot
The cable must with stand the test voltage & leakage
current should not exceed 2mA
Current Rating
HT ABC (Standard Sizes of Single core cable)
S. No. HT AB Cable Size (SqMM) Max. Continuous Load (Amps.)
1 35 106
2 50 150
3 70 190
4 95 230
5 120 265
6 150 300
7 185 345
Page 111 of 333

Authorization
compliance report provided as Annexure is to be duly signed by JUNIOR ENGINEER/Project
engineer and counter signed by SDO and the same has to be kept as record. The record may be
available with respective SDO & JUNIOR ENGINEER and should be presented for verification
during the audits.
Implementation
Repairing.
Review:
accordance with the revised standards.
CHECK LIST/ANNEXURE- HT ABC-1
Page 112 of 333

Cable jointing Process
Power cables
Cablesare used for the transmission/distribution of electrical power and consist of three major
components:
 Conductors
 Insulation
 Protective jacket
For cables operating at or above 6,000 volts between conductors, a conductive shield surrounds
each insulated conductor to equalize the electrical stress on the cable insulation. The construction
and requirements are specified in standards such as IS7098 and IEC 60502, IEC6084.
Shielded power cable components
Page 113 of 333

Functions of Each Component
 Conductor -- For transports energy
 Insulation – To Insulate phase to ground and/or phase to phase.
 Screening/ shielding – To Maintain electrical field in cables and conduct fault
current.
 Armour – To provide mechanical protection
 Jacket – To protect cable structure from environmental effects (water,
corrosion, humidity…)
Cable Screen – Theory

 No conductor shields or insulation shields are required for cables rated up to 2 kV.
 At 2kV and above a conductor shield is required. Modern conductor shields are mostly
an extruded semiconducting material that in effect smooth out the conductor to make it
look like it has a solid smooth surface.
 At 5kV an insulation shield may or may not be required depending on the cable type and
it’s application.
 Above the 5kV level an insulation shield is required in all recognized standards. The
semi-conducting component of an insulation shield, like the conductor shield, is an
extrusion of semi-conducting material over the outer surface of the insulation. This
shield controls the electrical stress within the insulation and prevents objects from
disturbing the stress at the insulation’s outer surface. An insulation shield is always
made up of two components, an extruded semi-conducting layer over the insulation and
a metallic component over that.
The important steps in the cable jointing of medium voltage XLPE insulated screened
armoured cable
a. Strip the jointing ends of both the cables to be done i.e. stripping of outer sheath, armour, inner
sheath, insulation screen, core insulation and conductor screen. Longer end will be 1050mm and
other end 750mm for 33Kv XLPE 3*400 sq. mm cable. Park the tubes 1000mm and 500mm then
1000mm at the longest side of the cable.
b. All the conductor cores shall be joint with the help of jointing ferrule/mechanical connector and
its crimping by suitable crimping tool.
c. Fill up the space between the ferrule and the core insulation and the crimped portion in ferrule
with semi conducting clay, so that it forms a smooth and round profile with 2 mm.
Page 114 of 333

d. Measure a distance of 20 mm on both sides of the semi-conducting tape. Apply stress grading pad
of 30mm width over the core covering 10mm of the semi conducting tape as shown in figure given
below.
e. Keeping conducting layer of core, wrap the self-amalgamating insulating tape so that the required
insulation thickness is built up. Ensure a tapered profile of the tape towards the semi conducting
layer of the insulation, the self-amalgamating tape should be stretched to 2/3 rds of its original width
while applying as shown in figure given below.
Page 115 of 333

f. Fill up the gap 5mm between self-amalgamating insulating tape and semi conducting layer of core
by stress grading pad of 30mm width as shown in figure given below.
g. Apply semi conducting tape one layer half over lapped about 10mm on one side of metallic
shielding to the other end in the same manner as shown in figure given below.
h. Wrap 2 layers of self-amalgamating insulating tape, each half overlapped to cover the semi
conducting tape. Stretch the tape 2/3rds of width while applying as shown in figure given below.
Page 116 of 333

i. Wrap one layer of copper wire mesh on the core to connect the copper tape from end to another
over the tapes as shown in figure given below.
j. Place the black stress control tube centrally over the joint. Starting at the centre shrink the tube
towards one end and then towards the other end until fully shrunk. Apply heat evenly throughout
the process. When completed adhesive will flow from the ends, wipe off excess.
Page 117 of 333

Role of Earthing in Power Distribution
Introduction
With power system becoming more complex, Fault level has also gone up. So in a substation, a low
resistance path to ground is necessary:
 To minimize the ground rise potential during fault

 To ensure proper operation of high speed relaying.
The low resistance path in sub-station is accomplished by the installation of an earth mat.
Moreover, proper grounding & bonding through low resistance ground is essential to facilitate
dissipation of unwanted signals from lightning, electrical surges and other transient pulses through
power lines, affecting communication system, computers, RADAR etc.
An appropriate earth system will safeguard both life & equipment.
The earthing system installation shall strictly comply with the requirement of latest addition of IE
Rules, Relevant Indian Standards & applicable codes of practices.
Earthing In Electrical System
 Earthing means making an electrical connection to general mass of earth.
 Earth forms an intrinsic part of electricity System.
 Earthing of electrical installation is primarily concerned with ensuring safety.
 Soil conductivity is an important consideration. Lower the resistivity, easier to get good
earth.
 The ground is more effective conductor than copper wire used in electrical circuit.
 Earth provides the shortest path for fault current to travel.
 Short circuits allows electrical current to by-pass its normal route. Under short circuit,
current follows the least resistance fault to ground.
Reason for Poor Earthing Practices:
 Inadequate understanding about technical requirement of earthing& Standards.
 Earthing has no role to play during normal conditions.
 Lack of compatibility between earthing requirement of electronic equipments& power
system.
 Lack of motivation & importance to engineers for keeping earthing& connections in
proper state.
Page 118 of 333

Why Earthing Important?
Earthing in a substation is extremely important for the safety of operating personnel as well as for
proper system operation.
 It provides safe passage to earth fault current to flow. E/F current flow through the earth
and may readily cause operation of fuse or E/F relay.
 It provides low resistance path to fault current to ensure prompt & consistent operation
of protective devices under fault current.
 It protects the equipment other than live parts from attaining potential. Under fault
conditions, frames & enclosures etc may attain high potential w.r.t ground. So these
non-current carrying parts should be connected to ground for the safety of the operating
personal & other human beings for discharging electrical energy to earth.
 It protects the equipment from over voltages, HV surges resulting from lightning &
other causes.
 It ensures safety of life from electric shocks by grounding all metallic structures and also
avoid hazardous voltage gradients by suitably designing the grounding system. The
potential of earthed body does not reach to dangerously high values during fault.
 It ensure that ground potential rise does not have any dangerous effect on
communication system.
 It plays an important role in increasing the reliability & continuity of supply service and
stabilizing the voltage conditions.
 It has means of discharging feeders &equipments to ground before proceeding with
maintenance.
Attributes Of Good Earth Connection
 Lowest soil resistivity.
 Low electrical resistance to earth.
 Good corrosion resistance.
 Ability to carry high current repeatedly.
 A reliable life of at least 30 years.
 Low loop impedance path of earthing.
Statutory Requirement of Earthing - IE RULE 1956
 All medium voltage equipment shall be earthed by two separate and distinct
Connections.
 All metal supports, all reinforced and pre-stressed cement concrete supports of overhead
lines and metallic fittings attached thereto shall be permanently and effectively earthed.
For this purpose a continuous earth wire shall be provided and securely fastened to each
pole and connected with earth ordinarily at three points in every kilometer, the spacing
between the points being as nearly equidistance as possible. Alternatively, each support
and the metallic fitting attached thereto shall be efficiently earthed.
Page 119 of 333

 Metallic bearer wire used for supporting insulated wire of low and medium voltage
overhead service lines shall be efficiently earthed or insulated.
 Each stay wire shall be similarly earthed unless insulator has been placed in it at a height
not less than 3.0 meters from the ground.
 As far as possible, all earth connections shall be visible for inspection.
 Each earth system shall be so designed that testing of individual earth electrode should
be possible.
 Resistance of earth system shall conform to standards for degree of shock protection
desired.
Vulnerable Points to Be Earthed
 The neutral point of each system through its own independent earth.
 Equipment framework & other non –current carrying parts.
 All extraneous frame work not associated with equipment.
 Earth point of LA’s ; CT’s ; CVT’s ; PT’s ; coupling capacitors , Power & Distribution
Transformers ; Switchgears ; Isolators ; Distribution poles ; Guard wires etc.
 Earth pits in a Sub-station to be interconnected to form a mesh.
 C&R Panels and switchgear panels.
Terminology
1. Earth conductor –A Protective conductor connecting the main earthing terminal to an earth
electrode which can sustain the maximum system fault current.
2. Protective conductor – A conductor used as a measure of protection against electric shock
and intended for connecting any of the following parts:
a. exposed conductive parts,
b. extraneous conductive parts
c. main earthing terminal, and
d. earthed point of the source or an artificial neutral
3. Neutral conductor – A conductor connected to the neutral of a system and capable of
contributing to the transmission of electrical energy.
4. PEN conductor – A conductor combining the function of both Protective and Neutral
conductor.
5. Earth Electrode – A conductor or a group of conductors in intimate contact with and
providing an electrical connection to earth.
6. Earth Resistance – The resistance of an earth electrode to earth.
7. Earth Leakage Current - The current which flows to earth or to extraneous conductive
part in a circuit which is electrically sound.
8. Step voltage – The potential difference between two points on earth’s surface (at a distance
of 1.0m), experienced by a person with the feet without contacting any grounded object.
Page 120 of 333

9. Touch voltage – The potential difference between a grounded metallic structure and the
surface potential at a point where a person is standing touching a grounded structure,
approximately one meter.
10. Earth Grid – A system of grounding earth electrodes consisting of inter-connected
connectors buried in the earth to provide a common ground for electrical devices and
metallic structures.
11. Earth Mat – A grounding system formed by a grid of horizontally buried conductors and
which serves to dissipate the earth fault current to earth and also as an equipotential bonding
conductor system.
Types of Earth Electrodes
 Depending upon the shape :

a) Pipe electrode
b) Rod electrode
c) Plate electrode
To obtain a low overall resistance the current density should be as low as possible in the medium
adjacent to electrode, hence dimension in one direction is made larger than other two, so a Pipe or
Rod has much lower resistance as compared to Plate of an equal area.
 Depending upon the material
a) MS/GI
b) Copper
The material shall be resistant to corrosion in the type of soil in which it is to be used. However, for
Power transformer neutral, electronics earthing, etc. copper is used due to higher conductivity.
Page 121 of 333

PIPE EARTH ELECTRODE
Page 122 of 333

PLATE EARTH ELECTRODE
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Types of Earthing
1. System Earthing – Providing earth to the entire system (connection between part of equipment
like neutral of transformer to earth) so as to ensure that potential on each conductor is restricted
such that it is consistent with the level of insulation applied. System earth resistance should
ensure efficient & fast operation of protective gear in case of fault so as to isolate the faulty
section and make the installation harmless.
2. Equipment Earthing – Providing earth to the entire system (connecting frames of equipment
like motor body, transformer tank to earth) to ensure freedom from shocks to the personnel in
vicinity and provide current carrying capability to accept ground fault current permitted by over
current protective system without creating a hazard to the building/installation
Selection of Earthing System
Separate and distinct earthing systems have low current flowing thru’ the measuring device such
as relays and long distances need to be covered. So a combined and Direct grounding system is
more effective than the individual Earthing.
a) Large spread areas – Buried earth conductors with localized earth rods shall be the solution.
b) Compact installations – Uniformly spaced buried conductors with as many earth rod
electrodes or mesh of earth conductor to meet the required resistance.
Factors Affecting Earth Resistance
Following factors may affect the value of earth resistance.
1. Resistance of the earth electrodes.
2. Contact resistance between the electrode & the soil
3. Soil Resistivity
a) Moisture content of the soil
b) Chemical composition of the soil
c) Concentration of the salts dissolved in the contained water
d) Grain size & distribution, and closeness of packing or the soil
e) Soil temperature
4. Geometry of earth electrode – To obtain Low overall Resistance, current density adjacent to
the electrode should decrease rapidly with distance from electrode. This is done by making
dimension in one direction large. Hence, pipe, rod or strip has much lower Resistance as
compared to Plate electrode.
5. Use of Crushed stone/Gravel layer – The crushed stone surfacing (0.08-0.15m in depth) is
used to retard the drying up of soil and increase the contact resistance b/w the person’s foot
and earth. This allows a higher touch and Step potentials.
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Earth conductor
Material -Conductor material does not affect earthing resistance except for deterioration of its size
due to corrosion. Therefore, the considerations are:
a) Resistance to corrosion in the surrounding medium
b) Conductivity to ensure satisfactory bonding resulting in negligible voltage difference along
the conductor
c) Material ruggedness
Cross-sectional area required for a certain fault current
Where,
I= value of fault current in amperes,
t= operating time of the disconnecting device in seconds,
k= factor dependent on material of conductor
Typ. Cross sectional area calculation for earth conductor
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Comparison of conducting materials
Earthing arrangement for pole mounted sub-station on DP:

Distribution transformer is the main component of substation / pole mount substation. Its protection
from unbalance current, voltage surges etc. is required for its healthy operation. Apart from that
protection of human & animal also keep in mind during installation of transformer. So earthing of
complete pole structure become mandatory. Generally 5 nos of earthing of Pole mount Distribution
Transformer carried out. Which are listed below.
1. Separate Earthing of DT Neutral (2 nos)

2. Separate Earthing of Lightening Arrester.
3. Separate Earthing of Transformer Body.
4. Separate Earthing of Pole Structure.
5. Separate Earthing of G.O Switch.
An Earthing arrangement for Pole mount DP is shown in picture below.
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EARTHING ARRANGEMENT FOR POLE MOUNTED SUB-STATION ON DP
Page 127 of 333

Limits of Earthing Resistance
Following are values of earth resistance considered appropriate for different electrical
installation
a) Large HV and EHV s/stns - 0.5 ohms
b) Industrial and Distribution s/stns - 2.0 ohms
c) Medium voltage systems(415 V) - 5.0 ohms
 The continuity resistance of the earth return path thru’ earth grid should be maintained
d) Large
as low as HV and to
possible EHVlimits/stns -
the rise of potential0.5 ohms installation above the potential
of earthing
of zero/remote earth during the passage of fault current.
e) Industrial and Distribution s/stns - 2.0 ohms
 However, in EHV s/stns in spite of low earth resistance, the GPR may be as high as
f)5kV. So thevoltage
Medium earth design has to V)
systems(415 be based- on the 5.0
tolerable
ohms limits of Step and Touch
Potentials.
 If the earth fault impedance does not permit the O/C devices to operate and can’t be
reduced further, then RCDs or ELCBs are used to disconnect the circuit at fault.
Range of tolerable current

a) Threshold of perception - 1mA
b) Let-go current - 1-6mA
c) Painful currents - 9-25mA
d) Causing Fibrillation - 60-100mA
 RCDs/ELCBs should be designed for currents below the Fibrillation threshold.

 A contact potential of 65V is within tolerable limit of human body for 10 sec. Hence,
protective device should clear this within 10 sec. So, as per standard practice the
earthing electrode/ mesh was designed for 1sec – 3 sec.
 A voltage of 240 V can be withstood for 100msec and should be instantaneously
cleared.
Check list Annexure-ERT-1
Page 128 of 333

FUSES
Introduction
A switching device, which by the fusion of one or more of its specially designed and proportioned
components open the circuit, in which it is inserted and breaks the current, when the same exceeds a
given value for a sufficient time. The term fuse covers all the parts forming the complete switching
device.
Description
Fuse is a safety device and the weakest part of the electrical system. It consists of a small link of soft
metal, which melts when excessive current passes through it. The fuse wires are usually bare wires
and made of lead and tin. Lead alloy for small current and tinned copper wire issued for large
current. Upto 3 amperes load, lead fuse wires are used, up to 15 amperes alloy of lead and tin is used
and above 15 amperes, tinned copper wires are used. If a short circuit occurs anywhere in the wiring
system, an excessive current flows through the wires and fuse and if fuse operates properly, it will
melt, cutting of the current before any harm can be done. If the fuse fails to operate, the wire may
become hot enough to ignite the insulation, possibly causing a fire and it may harm the appliances
and fittings connected in the circuit. Fuses have a second function. Besides protecting in the case of
short circuit, they protect in the case of overload. If too many appliances are connected to one
circuit, more current will flow through the supply wires than the wires were meant to carry and will
cause the wires to be burnt and appliances, accessories connected to the circuits will also be
damaged. In such cases, the fuse, if properly selected, will melt or blow, thus protecting the wires,
appliances, accessories etc.
Fusing factor
The ratio of minimum fusing current and the current rating of fusing element. Or
Fusing factors = Minimum fusing current /Current rating of fusing element. Its value is always
more than 1.
Principle of operation
The operation of fuse depends upon the heating effect of an electric current. When the electric
current is increased in a circuit due to short circuits or over loads, it increases the rate of heat
generation, which will increase the temperature of the fuse wire and thereby the rate of heat
dissipation increases from the exposed surface of the fuse wire. The final temperature reaches to
Page 129 of 333

such stage that the heat generation will be equal to the rate dissipation. If this temperature happens to
be above the melting point of the material for fuse wire, fuse must have operated
Selection of fuse wire
To select the proper fuse wire to be inserted in a circuit two factors viz. (a) maximum current rating
of the circuit (b) current rating of the smallest size of wire of accessories is to be seen, the fuse wire
inserted should be of size so that when the current with reference to factors (a) and (b) is increased, it
should blow out. The type of wire to be selected to use as a fuse wire depends upon the type of load
connected to the circuit i.e. steady load and fluctuating loads. The steady load covers the heating
loads and the fluctuating load consists of motor, capacitor and transformer loads, all of which take
transient over current when they are switched into the circuit. In steady load circuits, the fuse forms
only the protection part of the circuit. Therefore, the fuse rating should be equal to or next greater
than the ratings of the smallest cable used in the circuit. But if a number of fuse wires are run in
parallel to augment the rating of fuse, total rating should not be equal to the product of rating of and
strand and number of strands used. In fluctuating load circuits, fuse should allow the short time over
current to flow without blowing. For this, it is necessary to select fuses of rated current greater than
that of the cable of the circuit. The fuse wire should always be inserted in live wires or phase of the
circuit, or otherwise even if the fuse blows out, the faulty circuit will be fade and would cause
considerable damage in case of leakage fault.
Melting points of various metals
The melting point of various metals are given in table below:
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Current Rating of Fuse wire-
1. Copper Fuse wire
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2. Tinned Copper Fuse wire
Page 132 of 333

Autorecloser and Sectionalisers
Introduction:
An Autorecloser can reclose automatically after a specific set duration so supply restoration on
transient faults is quick. And on a dead fault the nearest Sectionaliser operates and the healthy
network gets disconnected from faulty network so the supply is restored in healthy part of network
in short time.
Autorecloser:
An autorecloser is a circuit breaker equipped with a mechanism that can automatically close the
breaker after it has been opened due to the fault current. Autoreclosers are used in coordinated
protection schemes for overhead power distribution circuits. These circuits are prone to transitory
faults such as nearby lightning strikes, wind-borne debris, birdages, kite fault and tree touching the
lines and any transient arc on insulators because of rain or fog.
With a conventional circuit breaker or fuse, a transient fault would open the breaker or blow the
fuse, disabling the line until a technician could manually close the circuit breaker or replace the
blown fuse. But an autorecloser will make several pre-programmed attempts to reenergize the line.
If the transient fault has cleared, the autorecloser's circuit breaker will remain closed and normal
operation of the power line will resume. If the fault is some sort of a permanent fault (downed
wires, tree branches lying on the wires, etc.) the autorecloser will exhaust its pre-programmed
attempts to re-energize the line and remain tripped off until manually commanded to try again.
90% of faults on overhead power lines are transient in nature and can be cured by auto reclosing.
The result is increased reliability of supply.
Sectionaliser:
Sectionaliser is a load break switch but it can be opened on load but in the event of existing fault in
line it can be programmed to open in off load condition. A sectionaliser is not designed to interrupt
fault current. The sectionaliser records the fault current and circuit interruption by the autorecloser.
After one autoreclosing cycle if the fault current persists, the sectionaliser will open its branch
circuit during the open period of the autorecloser, thereby isolating the faulty section of the circuit.
In second reclose attempt the supply restored in healthy Ckt.
Scope:
This operational guideline is intended to carry out the fundamental checks on Autorecloser for its
prepare the action plan and ensure the availability of necessary tools and tackles to carry out this
activity.
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Prerequisites:
 Ensure that necessary permit has been taken. Power System Control Centre is
responsible for providing outage and PTW. The working party is responsible for
ensuring isolation. Ensure that the line is de-energized & grounded before starting any
work on Autorecloser main unit.
 Working party should ensure the availability of proper tools and accessories, safety
 Working party should ensure the adequacy of the platform/ space to work. In Case of
unsafe condition and space constrain tower wagon shall be used.
Directives, Checks and Tests:
Directives & Checks:
1. Indicator position shall change according to the

on and off condition of Switchgear. Any issues
related to non-movement of indicator shall be
Mechanical
1 informed to Autorecloser team at the earliest.
position indicator
2.Sub-Divisions will be responsible for intimation
of issue and Sub-Division to extend support for
timely rectification of issues.
1. The conductor shall be connected to bushing with

suitable wedge clamp connectors.
Connection of 2. Use of binding wires must be avoided.
2 conductor with 3. All Connections shall be tightly fixed.
bushings 4. Responsibility center is Sub-Divisions and for
new installations, while handling over Sub-Division
shall ensure the same.
PTCC panel shall 1. PTCC panel shall be kept clean.
be locked and 2. All unused openings shall be plugged.
3 cleaned/dusting in 3. Sub-Division shall be responsible for dusting of
every six months at panel shall be done on every occasion to protect the
least electronic cards inside.
The Battery cell 1. In case of any unhealthy condition of battery
4 and connecting link voltage and cell condition, Sub-Division shall
status shall be inform to autorecloser team and can get it issued
Page 134 of 333

healthy. from DHBVN stores.

2. The battery terminals and the links shall be kept
intact and properly connected in case any rework
required autorecloser team shall carry out the same.
3. Ensure that all of the battery terminal connectors
are secure and in good condition.
1. Sub-Division to ensure that earth connections
Earth Connections should be properly tightened and earth resistance
5 should be <1ohm.
and earth resistance
2. Autorecloser team may extend any help required
to get the same done.
1. The Switchgear shall be always in position to be
operated from PTCC panel and Sub-Division shall
The operation from inform any operational issues to Autorecloser team
6
Local PTCC panel 2. Sub-Divisions to extend support and arrange for
tower wagon if required for timely rectification of
issues.
1. The Switchgear shall be installed in such a way
that the safety of personnel’s in vicinity of
switchgear must be addressed.
2. The PTCC panel should be installed at such a
location where any passerby vehicle shall not
The Switchgear damage the panel.
7 Installation and 3. OEM supplied accessories must be properly
safety utilized while installation, like mounting bracket etc.
4. The check list given in annexure and test given
bellow shall be conducted and checked before
energizing and handling over.
5. Intimation of the installation of equipment shall
be given to Autorecloser team for records of
commissioning date and sr. of equipment’s.
Any network In case Sub-Division want to make any changes in
alterations like existing location of Autorecloser and Sectionaliser
8
change of location same shall be inform to Autorecloser team for
of equipment updating records.
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Tests:
1 IR Test main Switch gear Should be >1Gega Ohm

2 Earth Resistance Should be <1 ohm
3 Contact Resistance Should be < 120 micro ohm
Should be >5Gega Ohm on HT
4 IR of PT and PT secondary
and Secondary > 50M ohm.
5 Relay testing and tripping circuit Should be healthy.
6 Battery health Should be healthy.
* Note: – All tests shall be carried as per condition of switchgear with the help of protection
department. Requirement of testing shall be decided by Sub-Division with help of protection data.
Maintenance Activity and check lists:
Routine Maintenance activity and check list: to be filled by Sub-Division and Autorecloser Team
S.No Check Status
1 Operational checks
a Position Indicator (Mechanical) OK Not OK
2 Electrical checks
i. Check the date and time in PTCC OK Not OK
LED indication on PTCC Breaker Close /
ii. OK Not OK
Open
Battery voltage ( Aux supply should be turn Should be
iii. OK Not OK
off ) 24VDC
iv. Auxiliary supply Normal Abnormal
v. Check history logs events in panel OK Not OK
vi. Current values on PTCC ( After switch ON ) OK Not OK
vii. Voltage values on PTCC ( After switch ON ) OK Not OK
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S.No Check Status
Pressure
viii. Pressure reading of SF6 on PTCC OK Not OK
( RL Type only ) ____KPA
3 Environmental checks
i. Visual inspection for missing parts OK Not OK
ii. Cleaning of PTCC ( dust etc ) Yes No
iii. Cable entry point sealed in PTCC Yes No
iv. Tie / clamp support to umbilical cable OK Not OK
v. Visual inspection of any damages Yes No
vi. Presence of Earthing on PTCC panel and PT OK Not OK
vii. Presence of PT bushing insulated Caps OK Not OK
4 Status of Battery cell terminals, connecting links OK Not OK
5 PTCC panel door intactness (window + Main door) OK Not OK
6 Lock of PTCC panel door OK Not OK
7 Contact Life Status on WSOS Value ______%
8 Cleaning/dusting Modem
9 Cleaning/dusting of SIM card in Modem
Planned Maintenance Activity and check list:

Please ensure Switchgear and line is dead, earthed and in OFF position before carry out any work.
To be filled by Sub-Division and autorecloser team.
S. No Checks Status
1 Operational checks
i Switchgear ON/OFF through PTCC OK Not OK
ii Switchgear ON/OFF manual (in 'Sectionaliser/ RL series' only) OK Not OK
iii Mechanical Interlocks OK Not OK
iv Switchgear tripping through Emergency Lever (in U Series OK Not OK
Page 137 of 333

S. No Checks Status
only)
v Position Indicator (Mechanical) OK Not OK
2 Electrical Test
a Local / Remote - ON / OFF OK Not OK
b LED indication on PTCC Breaker Close OK Not OK
c LED indication on PTCC Breaker Open OK Not OK
Electrical interlock - Enable / Disable switch OK Not OK OK
d OK Not OK
Not OK
e Battery voltage ( Aux supply should be turn off ) ( 24VDC ) OK Not OK
f Auxiliary supply Normal Abnormal
g Check/ Download WSOS history logs Yes No
h Current values on PTCC ( After switch ON ) OK Not OK
i Voltage values on PTCC ( After switch ON ) OK Not OK
j Pressure reading of SF6 on PTCC ( RL Type only ) OK Not OK
k Check PT fuse intactness and continuity OK Not OK
l ON / OFF operation through Battery OK Not OK
a Visual inspection for missing parts OK Not OK
b Cleaning of PTCC panel, ACR ( dust etc ) OK Not OK
c Connection Check of Plugs and CAPM compartment OK Not OK
d Cable entry point sealed in PTCC OK Not OK
e Cable entry point sealed in Switchgear OK Not OK
f Stress on bushing due to cable/conductor connection OK Not OK
g Method of Conductor connection on bushing OK Not OK
h Tie / clamp support to umbilical cable OK Not OK
i Terminal Connectors OK Not OK
Page 138 of 333

S. No Checks Status
j Visual inspection of any damages OK Not OK

k Visual inspection of any hot spot OK Not OK
l Presence of Earthing OK Not OK
m Earthing Resistance ( Pit ) test OK Not OK
n Tightning of Cable clamps / connectors to bushing OK Not OK
o Condition of Male/Female Pins on plugs (PTCC / S/G) OK Not OK
p Clearance of PT with Guard wire OK Not OK
q Presence of PT bushing insulated Caps OK Not OK
r Contact Life Status on WSOS OK Not OK
6 Condition of Electronic Module - OK Not OK
a CAPM / SCEM / CCEM / OCPM OK Not OK
b MDIM3 / MDIM2 OK Not OK
Status of battery cells terminals, links and any requirement of
7 OK Not OK
petroleum jelly if not ok
8 Modem Functionality OK Not OK
9 Dusting of Modem and SIM card OK Not OK
Authorization
The SDOs will ensure that the operational directives and guidelines are followed at every level.
During installation and taking handling over the check list provided in 5.2 shall be duly filled by
supervisor and checked by JUNIOR ENGINEER/project engineer and counter signed by SDO and
the same has to be kept as record. The record may be available with respective SDO & JUNIOR
ENGINEER and should be presented for verification during the audits.
Implementation
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The JUNIOR ENGINEER/SDO shall be responsible for implementing these operational guidelines
while planned maintenance and commissioning of Autorecloser and Sectionalisers. Detailed record
of the activity has to be maintained.
Review:
accordance with the revised standards (IS & IEC) and also from learnings gained during the routine
trouble shooting and commissioning activities
Annexure- AR-1 Attached
Page 140 of 333

AT LT Voltage Level
LT ACB
Introduction
LT ACBs are used in our system for distribution at 415 V level. The incomer cables from the
Distribution transformers are connected to the incoming terminal of one or more ACBs and the
feeder circuits are taken out from the outgoing terminals of ACBs. The various ratings of LTACB
widely being used in distribution system are 400A, 800A, 1250A and 2000A. The guaranteed
technical particulars are as follows:
S. No Description Requirement
1 Rating 400A, 800A, 1250A, 2000A
2 Type of ACB Fixed type, Manually operated
3 Type of Release Thermal magnetic release
4 Overload Release Setting 50/60%-100%
5 Utilization category B
6 No of Poles 3
7 Rated Operational Voltage 415V
8 Rated Impulse withstand Voltage 8KvP
9 Rated Ultimate Short Circuit Breaking 50KA rms

capacity( Icu)
10 Rated Service Short Circuit Breaking 100% of Icu

Capacity(Ics)
11 Rated Insulation Voltage 1000V
Page 141 of 333

S. No Description Requirement
12 Rated making Capacity 105 KAP
13 Material of Busbar Aluminium
14 Maximum permissible temperature rise 80° C (with an ambient

temperature of 40 deg C)
15 Minimum clearances between phases 25.4 mm
16 Minimum clearance between phase and 19.4mm

earth
The incoming and outgoing terminals are designed for cables as mentioned below.
S. No Rated Phase/ Neutral Size of I/C Cable Size of O/G Cable

Current (sq mm) (Per Phase) ( Sq mm)
1 400 1RX1C 630 or 4CX300

4CX300
2 800 1RX1C 630 4CX300
3 1250 2RX1C 630 4CX300
4 2000 3RX1C 630 4CX300
Receiving and Handling

When an ACB is received please check the following and report immediately on non-conformity.
1. Check whether the breaker is fully complying with the order specification as the operating
manual is available with each ACB.
2. Check for any loss or damage during transportation.
Storing
It is recommended that the breaker is installed as soon as it is received, but if it is necessary to store
it for some period, the following points to be observed for safe storage-
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 Keep the breaker in warm dry room, as absorption of moisture can deteriorate the
insulating materials.
 Store the breaker with its closing springs discharged.
 Keep the breaker in clean place free of corrosive gases, dirt and dust. It is recommended
that the breaker be kept packed in the polythene packing wrapped around it during
dispatch.
 Place the breaker in normal position on a level place.
 Do not place the breaker directly on the floor. Use a pellet for keeping the breaker and
ensure that water ingress cannot happen.
Transportation and Installation at site

While transportation and installation the following points are to be taken care of.
 Do not lift the breaker with ordinary crane hooks or ropes but by using hands.
 Keep the breaker away from impacts and shocks during transportation.
 Make sure that the surface on which the breaker is to be placed is leveled.
 Ensure proper fixing of ACB, to the channels on which it is placed.
 The earthing bolts of the ACB are to be connected to the earthing bolts of the ACBs on
either side, if the ACB is being placed between two ACBs, else if placed at one side, one
earthing bolt will be connected to the body earthing conductor of the substation and the
other end will be connected to adjoining ACB.
 Ensure complete tightness of lugs, fixed on ACBs and take care that the contact area is
sufficient.
 After completion of work, the handle (where applicable) is to be kept at office and the
ACB is to be kept in locked condition only.
Operation
Different ACBs have different operating procedure. The operating manual of the respective ACBs
are to be consulted for proper guidance.
Tripping of Short Circuit Magnetic release: A protection is required against short circuit faults,
where the current may be many times the rated current. It becomes desirable that the breaker trips
with minimum delay unless definite time delay is envisaged for the discrimination of up and down
stream breakers.
The Magnetic instantaneous trip fitted in the breakers is a U shaped magnetic core placed around
the load terminal of the breakers and across the open side of the core, an armature is provided. The
movement of the armature is controlled by a spring. The settings are pre-determined and cannot be
changed easily at site.
Page 143 of 333

Maintenance and overhauling
Maintenance of ACBs are to be carried out as per the periodicity mentioned in the Annual
Maintenance schedule. Visual Checks to be carried out:
Action to be taken in case of
SNo Parameter Points to be checked
any anomaly
a) ACB must have a cover and it a) Report for replacement of

should be locked. cover if found missing. To
b) Check for any visual deformity/ lock ACB if found unlocked.
flash mark/ crack/ dust on arc b) Clean the dirt and dust
chutes, arcing contacts and moving using dry cloth/blower. For
contacts. any substantial damage report
for repairing.
Physical c) Check the point of entry of
1 busbars into the enclosure. The c) If discrepancy found,
Condition
busbars should be properly tapes please arrange for covering of
and the entry should be sealed with the busbar portion with color
sealants like silicon grease. coded tapes and sealant.
d) Check tripping circuit, CTs, d) Report for repair if
release (if applicable). wires/CTs are found damaged
e) Status of Enclosure to be /dislodged. The tripping
checked ( damage/ rusting, etc) setting is to be checked by JE.
e) Any substantial damage to
Page 144 of 333

Action to be taken in case of
SNo Parameter Points to be checked
any anomaly
be noted and reported
The support structure to be re
The ACBs should be placed on
Alignment and levelled and the ACB should
2 leveled structure and secured
Support Structure be secured with proper nut
properly
bolts/welding
Lugs to be changed in case of
any heating/ pitting observed.
Busbar to be cleaned using
emery paper before
reconnecting the cables.
All incoming and outgoing cables
Dressing and Proper tightening and taping
to be crimped and connected
3 Crimping of Main to be ensured. In case the nut
properly to the incoming and
& Looping cables bolts used are found
outgoing busbars.
incompatible to the lug holes,
proper sized nut bolts are to
be used. Busbars, if found
charred, are to be reported for
replacement.
Earthing to be done as mentioned
Remedial action to be taken
4 ACB Earthing earlier in part D ( Transportation
on non-conformance.
and Installation at site, point no-5)
Safeguarding of Bakelite/ FRP separator plats to be Damaged separators to be
5
Bare Terminals used where clearance are reduced replaced
Check list/Annexure-LT ACB.
Page 145 of 333

LT UNDERGROUND CABLES
Introduction
The underground cable network of any electricity distribution utility is a vital component of the
LV/HV network of the system. The reliability of the underground distribution network directly
affects the reliability of the overall system and ultimately the overall customer satisfaction.
Scope:
The operational guidelines involved in Testing & Repairing of Cable faults being carrying out for
maintenance of electricity distribution system.
Prerequisites:
 Ensure that necessary permit should be taken. Site In-charge is responsible for ensuring
isolation of the faulty cable for both ends & providing the PTW. Ensure that the cable is
 The workman should ensure the availability of proper tools and accessories, safety
Directives & Checks
Abnormality Causes/ Effect Preventive-Corrective action plan
1. Flash over due to Phase to phase &

Phase to earth clearance at cable Ensure sufficient clearance
termination
2. Termination failure due to Core Ensure core crossing below cut
crossing above cut back area at cable back area at cable termination
termination
Electrical stress
Ensure cleanliness of
3. Termination failure due to
Contaminated surface of terminations terminations

4. Cable failure due to Cable testing at
high voltage(DC) Voltage (Refer table2)
1. Stress develop due to Improper Ensure Proper Bending radius

Mechanical
Bending Radius (Refer table1)
stress
2. Stress develop due to Mechanical Ensure proper depth
vibrations (Refer table3)
Page 146 of 333

3. Stress develop due to Improper cable Ensure proper cleating

supports
Ensure recommended Loading
Insulation degradation due to overloading
(Refer table4)
Ensure proper
Thermal Insulation degradation due to Hot spot at
joints & Terminations Tightening/crimping of Lugs &
stress
Ferrules
Ensure Cable earthing connected
Insulation degradation due to Improper
Earthing connections with sub-station earthing
External
Insulation Damaged by external agency Ensure Patrolling of cable routes
damage

insulation/ cable failure, Corrosion in Ensure Lug seal to be intact at
Water ingress
cable conductor & Armor due ingress of outdoor termination.
water

PILC PVC XLPE
Type of Core 1C 3C 1C 3C 1C 3C
Upto 1.1 KV 20D 15D 15D 12D 15D 12D
‘D’ Diameter of the cable

Tests on Cables during fault localization, after repairs or when network modification is done
Test 230/440 V
Megger Test Phase to ground and phase to phase to be tested with 1KV
Megger for 1 Minute/or till reading stabilizes. Minimum IR
values should be 50M Ohms.
Depth of the cable

LT cable (1.1kv) 0.6 m
Page 147 of 333

LT Cables Current Rating
Current Rating of AL PVC Current Rating of
No. of Size cables in Amp AL XLPE cables in
S No. Amp
Cores (Sqmm)
AIR Ground AIR Ground
1 2 2.5 19 22 37 37
2 2 10 42 48 64 62
3 2 25 70 78 111 104
4 4 25 63 66 91 82
5 4 50 94 96 135 116
6 4 95 139 144 210 171
7 3.5 95 139 144 210 171
8 3.5 150 184 183 277 217
9 4 150 184 183 277 217
10 3.5 240 252 239 379 284
11 4 240 252 239 379 284
12 4 300 283 265 432 319
Authorization
The SDOs will ensure that the operational directives and guidelines should be followed at every
level. The compliance report provided as Annexure-I is to be duly signed by JUNIOR ENGINEER
and counter signed by SDO and the same has to be kept as record. The record must be available
with respective SDO & JUNIOR ENGINEER.
Implementation
Repairing.
Review
The XEN and above shall review this directive every two years or as necessary in accordance with
the revised standards (IS & IEC).
Check list/Annexure-LT UG Cable
Page 148 of 333

LT OVERHEAD LINES
Introduction
Overhead lines are the most cost effective and frequently used carriers for electric energy.
Exposure to environment accelerates deterioration; if the fault is not detected and repaired
quickly, some of it will degenerate into serious problems with time. To increase line loading and
quality of power supply, frequent inspection program is required, to locate and repair any
significant failure at the earliest possible stage.
Frequent failure in the Overhead lines can cause extensive damage to the insulator and other
electrical & earth joints which not only interrupts electricity supply but also results in large
revenue losses. Poor/inadequate maintenance in the areas of pole, span length, non-tension
electrical joints, conductor spacing, pole stay leads to the instability in the electrical and
mechanical parameter which reduce the life of the line. With appropriate on site actions, like
proper maintenance procedure, the useful life of the overhead lines can be extended.
Scope
This operational guideline is intended to carry out the fundamental Line Survey / Checks for its
prepare the action plan and ensure the availability of required materials, tools and tackles to carry
out this activity.
Prerequisites:
 Ensure that necessary permit has been taken from SDO/JUNIOR ENGINEER who is
responsible for providing outage and PTW.
 The PTW has to transfer to Working personnel after ensuring de-energization, isolation
and properly grounding the network where the activity has to carry out.
 The Working personnel should ensure the availability of proper tools and accessories,
 Clearance
Minimum clearances from any accessible point
1 The vertical clearance from the highest point 2.5 m
2 The horizontal clearance from the nearest point 1.2 m
Minimum Ground Clearance
1 Across the street 5.8 m
2 Along the street 5.5 m
3 Line erected elsewhere (Bare) 4.6 m
4 Line erected elsewhere (Insulated) 4m
5 Line crossing 11 KV & LT line 2.4m
Page 149 of 333

Current carrying capacity of conductor
Notes:-
Conductor current ratings may be interpolated for cross sectional areas between those shown in the
Table.
*Conductors with at least one ‘Type A’ stranding shall be used for general wiring of craft.
Conductors with Type B stranding shall be used for any wiring where frequent flexing is involved
during use.
Checks & Directives: LV O/H Feeders
Line Support
a) Pole – 9 m
1
b) Base plate (450mm×450mm×75mm) a) Depth of the Pit should be1/6 of
c) Stay the pole size.
Page 150 of 333

i. GI wire b) Pit filling concrete ratio 1:3:6

ii. Guy/Egg Insulator/Stay insulator c) Pole should be erected straight
iii. Tension screw d) Stay angle should be min.30°
iv. Anchor hook max 45°& should be fix at
v. Stay collar every pole where the line has
vi. Base plate deviated by more than 5°,End
d) D-Clamp. poles & Branch out/tee off pole.
e) Strut Pole e) Strut pole & flying stay should
f) Anti-climbing safety device be erect at the place where there
g) Mid-Span Pole is no provision for stay.
Pit filling content ratio 1:3:6 f) Tension screw, Stay collar,
Anchor hook and all hardwire
fixing Nuts& bolts to be checked
g) All thimbles shall be of proper
size and must be crimped with
help of crimping tool.
h) D-Clamp at end of conductor
span on pole shall be properly
prepared and tied using PG
clamps.
i) Wherever the span length is
more or conductor sag is high,
mid-span pole shall be used for
strengthening the network.
Line Hardware :
h) Insulator
i. Large Shackle for DOG &
RACOON
ii. Medium Shackle for RABBIT &
SQUIRREL
iii. Porcelain /PVC bobbin
i) Double line X- arm
2
j) Shackle strap - at section & end
pole
k) D-Clamp-for fixing shackle insulator
l) Line spacer FOR PHASE
CONDUCTOR
m) Wedge connector - for M/L Jumper
connection
n) Mini wedge connector - for cable
Page 151 of 333

connection for O.H Distribution

Box.
o) Bolts & Nuts –suitable sizes for
fixing hardwire
p) GI Washer-
Phase conductor shall be as per required
load and Neutral & Street .light shall be
3 Bare Conductor
of one rating lower. Earth conductor
shall be of 4 SWG
It should be depend on the size of the
conductor and pole height/type to
maintain min. Sag & specified ground
Span Length clearance.
4
It would be 40 m for urban & 50 m for
rural areas for 9 m PCC pole. If distance
between two poles are more then mid-
span pole shall be installed.
5 Section of Line Should be 4/5 span
Earth connections should be properly
tightened with all the metal part and
guard wire. If any Joint has observed in
the running portion of GI wire, it should
6 Earthing and earth resistance be changed. Earthing should be done on
every 5th pole & earth electrode should
go up to water level.
Earth Resistance value should be <1
Ohm.
Joints/Jumper
Conductor should firmly tighten using

PG connector of appropriate size.
Snapped/broken conductors shall be
bind using same size conductor. This
method incorporates binding of two
conductors together with aluminium
7.
a. Mid span joints wire. Unskilled labor and negligence
tends to improper joint formation. The
following activities also loosen the
joints and attention shall be paid-
 Loose connections
 Improper Binding.
 Faulty method of construction
 High Wind speed
Page 152 of 333

 Pole bending
 Increase of sag tension
 Substandard material for
jointing
In perfect joint, due to minimum
resistance, current smoothly flows
through the conductors, generating
minimum heat.
Damaged service line to be
replaced and joint in service line
covered with insulated tape, T-
joints or straight joints.
Jumper should be of the same conductor

or next higher size of in-coming cable &
should be join by C-wedge connector.
b. Jumper joints This method incorporates binding of
two conductors together with aluminium
wire in a semi-circular loop across the
pole.
8. Anti-climbing device Should be fixed as per standards.
All metal part should be paint by red
9. Painting & Pole Numbering oxide and Aluminium paint & pole has
to be numbered.
Danger plate should be fixed at All pole
10. Danger plate
as per standards.
Cable cleat & cable supporting pipe
12. UG Cable cleat, cable supporting pipe should be provide at the pole where
cable has terminated.
Feeder identification has to be done in
case there is more than one circuit on
13. Feeder Marking
the same pole. Identification tag should
be fixed on alternate pole.
Plinth/Muffing should be done on every
14. Pole base plinth/ muffing
pole as per the site condition.
Adequate support (Stay or Strut)
provided to poles wherever required.
15 Stay/Strut support for Pole Every 5th pole must having stay/strut
support. Erection of stay pole shall be as
per attached drawings in HT section.
Spacer (Wooden/PVC) support for
16 LT Spacer phase conductors shall be used. 4 Spacer
support/Span shall be used.
Page 153 of 333

Adequate protection of phase

conductors shall be available for
minimizing any accidentally
falling/snapping of conductor to ground.
Details regarding guarding has been
17 Guarding of conductor
provided in 33 kv section.
Guarding of conductor is mandatory for
Rural/Urban residential area and
Agriculture field where road crossing
and canal crossing is available onsite.
U type guarding for service connection
18 U type Guarding/ Jumper is to be introduced for long life of the
conductor and less faulty network.
Tests
1 Earth Resistance
a) Individual earth Should be <1 ohm
b) Continuous earth Should be < 5 Ohm
* Note: – Earth resistance tests to be carried out once in a year
Maintenance Activity
General Maintenance
 Check visually, the condition of Pole base & alignment of pole. If the pole is tilted,
should be straighten & rammed the pole base with brick bats after digging the earth
around the pole base. If any bend occurred at the mid of the pole, should be changed &
new pole to be erected.
 Check visually the condition of existing stay
 Check the Condition & size of GI wire. It should be 7/10 SWG.
 Check the Condition of Guy/Egg Insulator-if any damage observed or is missing, it
should be fixed/replaced.
Page 154 of 333

 Check the Condition of tension screw-if any damage observed, it has to be changed.
Tighten the turn buckle if required.
 Check the condition of anchor hook.
 Check visually the Line Hardware
 Condition of Shackle Insulator-if there is any crack, flash mark on the surface of the
insulator, it should be changed.
 Condition of Pin insulator spindle- if any damage or bend happened, it needs to be
changed. Check the tightness of the fixing nuts.
 Condition of Top hamper- if any tilt observed at top hamper or any damage occurred to
the metal part, it has to be change. Check the tightness of fixing nuts bolts.
 Condition of the Double line X-arm. if any damage occurred on X-arm or on the fixing
clamp, it has to be changed. Check the tightness of the fixing Nuts, bolts
 All metal parts to be painted by Primer &Aluminium paint for increasing the durability
& life span of the same.
 Visual inspection of bare conductor -if any damage occurred on the conductor, it to be
replaced with the same conductor through sleeve joint & the nos. of joint is limited to
maximum 2 per span.
 Use of Line Spacer to avoid fall of snapped conductor to ground & also maintaining
equal conductor spacing.
 Span length should be maximum 40 m. If the length longer than it, a mid span pole
should be provided.
 Line should be sectioned at every 4/5 span, if more, it should be reduced to 4/5 span.
 Visual inspection of Earthing should be carried out. If any damage occurred on GI wire,
it has to be replaced with a new complete earth electrode. If there is any joint observed
at earth wire, either the wire or the complete earth electrode has to be changed. Also,
tighten all joints on earth set. Resistance value of earth shall be measured &It’s value
would be < 1 Ohm.
 Visual inspection of Earth wire- if any damage/broken happened, it would be re-drawn
by 4 SWG GI wire.
 Inspection of Joints – Jumpering should be done by same conductor & will be jointed by
suitable C-wedge connector. Mid span joint has to be done by Suitable Sleeves & the
joint is limited to 2 no per span.
 Cable mounting on OH feeder-The cable should be mounted on pole structure through
GI pipe and must be mounted with clamps/STP. Cable be taken upto top of line and
jumper at cable end be through properly crimped lugs and fitted with C-wedge
connector with line.
 Service line should be limited to 8 nos.perpole,if the above exceeds the latest instruction
followed by DHBVNsalescircular.
Page 155 of 333

 During connection of service cable with the distribution box, the cable/conductor surface
(after opening the insulation) should be cleaned properly and should apply anti corrosive
grease before termination on distribution box.
 Configuration of line
Vertical configuration :-The line should be R,B,Y & Street light should be from top. The Neutral
& Earth wire has to be drawn on Double line X-arm run parallel with each other & both are
connected with each other by 4 SWG GI wire & N-wire. The same should separate with earth wire
by using bobbin insulator.
Authorization
The SDOs will ensure that the operational directives and guidelines should be followed at
every level. The survey report is to be duly signed by JUNIOR ENGINEER and counter
signed by SDO. The captured record must be available with respective SDO & JUNIOR
ENGINEER.
Implementation
The SDO shall be responsible for implementing these operational guidelines while execution
of maintenance activity.
Review
The XEN and above shall review this directive every two years or as necessary in accordance
with the revised standards (IS & IEC).
Check list/Annexure-LT OH Conductor
Page 156 of 333

LT ARIAL BUNCHED CABLE (ABC)
Introduction
The AB cable network of any electricity distribution utility is a vital component of the LV network
of the system. The reliability of the AB cable distribution network directly affects the reliability of
the overall system and ultimately the overall customer satisfaction.
Scope
The operational guidelines apply to site engineers & all of the workmen, who are involved in
Testing & Repairing of Cable faults, carried out during maintenance or breakdown activity.
Prerequisites
 Ensure that necessary permit has been taken. Site-in charge is responsible for ensuring
isolation of the faulty cable from both ends & providing the PTW. Ensure that the cable
is de-energized, isolated & grounded.
 Patrolling of AB cable feeder may be conducted to identify & removal of unauthorized
tapings before starting of the work.
 AB cable joints should be made properly. AB cable should not be jointed temporarily. In
case of emergency, proper joints must be made immediately. For jointing of Messenger
wire, mid span joint sleeve should be used instead of binding wires
 The in-charge should ensure the availability of proper tools and accessories, safety
Laying of AB Cables
It may be ensure that AB cable should not be dragged on roads/ footpaths etc. It must be laid by use
of rollers & pulleys. In case the AB cable is laid through trees/ vegetation area, branches may be
trimmed to avoid abrasion on AB cables. OH distribution box (3-Φ /1-Φ) should be mounted on
pole for giving service connection. Incoming cable of suitable size for Distribution box should be
jointed with ABC by Mini wedge connector/IPC.
Page 157 of 333

Directives & Checks
Flash over due to Phase to Ensure sufficient clearance

phase & Phase to earth
clearance at cable termination
Ensure 1ɸ AL. conductor PVC
insulated unarmoured cable with
thimble is used for connection
between Earth Braids & Messenger
wire.
ABC /Termination failure due
Electrical stress to improper connection between In existing design i.e with copper
Earth braid at End termination tape screen, 1Run X 25 sqmm cable
& Messenger wire.
may be used at every termination.
In New design i.e with AL wire

screen, 2Run X 50 sq mm cable may
be used at the alternate termination.
Termination failure due to Ensure cleanliness of terminations

Contaminated surface of
terminations
Cable failure due to Cable
testing at high voltage(DC) Voltage (Refer table2)
Ensure Proper Bending radius (Refer

Stress develop due to Improper
Bending Radius table1)
Stress/ Abrasion develop due to Ensure proper clearance between

Mechanical stress
improper clearance between
poles & ABC
poles & AB cable suspended on
suspension clamps
Stress develop due to Improper Ensure proper span length
Span length
Insulation degradationEnsure
due tor recommended Loading (Refer table3)
overloading
Thermal stress
Insulation degradation due to Ensure proper Tightening/crimping of
Hot spot at joints &
Terminations
Page 158 of 333

Lugs & Ferrules
Ensure ABC & Messenger earthing

Insulation degradation due to
Improper Earthing connections connected to Earth/ Ground
Insulation Damaged during Ensure use of Rollers/ Pulleys and

External damage installation due to improper Rope during installations.
Laying practices.
Water ingress Leakage current through the Ensure Lug seal to be intact at outdoor
cable Insulation/cable failure, termination.
Corrosion in cable conductor &
Armor due ingress of water
Clearly check the phase of cable 1 line represent R phase, 2 line represent Y phase and 3 line
represent B phase.
Earthing to be provided on 4thor 5th pole though 4SWG GI wire connected from Neutral
through insulated piercing connector
Voltage Level ABC
1C 4C
Upto 1.1 KV 15D 12D
‘D’ Overall Diameter of the AB Cable

Testing of AB cables
S. No Test LT ABC
Phase to ground and Phase to Phase should be tested with 1 KV

1 Meggar meggar for one minute or till reading is stabilized. Minimum IR
value should be 50 M ohms.
2 Hi pot Not applicable
Page 159 of 333

Current Rating
LT ABC (Values as per IS : 6474 – 71 & IS : 7098(1) 88 )
Clearly checking the phase of cable 1 line for R phase, 2 line for Y phase and 3 for B phase.
S. No LT AB Cable Size Current Rating @ 40 ⁰C
1 3x150+1x120 Sqmm 273A
2 3x95+1x95 Sqmm 235A
3 3x70 +1x70 Sqmm 190A
4 3x50 +1x35 Sqmm 149A
5 3x25 +1x25 Sqmm 99A
6 3x16 +1x25 Sqmm 60A
Authorization
The SDO will ensure that the operational directives and guidelines should be followed at every
level. The survey report is to be duly signed by JUNIOR ENGINEER and counter signed by SDO.
The complete record must be available with respective SDO & JUNIOR ENGINEER.
Implementation
The SDO shall be responsible for implementing these operational guidelines while execution of
maintenance activity.
Review
The XEN and above shall review this directive every two years or as necessary in accordance with
the revised standards (IS & IEC).
Check list/Annexure-LT ABC
Page 160 of 333

LT METERING & SERVICE CABLE
Quality Control Checks on Meters and Metering System:
Electronic Energy meters are installed for all consumers for recording energy used by consumers.
Electronic energy meters of class 1 accuracy shall be provided at all consumers premises.
The entire metering system needs to be regularly monitored to prevent any loss of revenue and to
analyze transmission losses. Analysis of transmission losses helps in taking corrective steps in
reduction of losses and improving the efficiency.
M&P unit under SE (M&P) will be normally testing the meters and the metering system
periodically (once in 2 year). Since the metering system at consumer end have commercial
implication, there should be proper sealing arrangement for meters and metering system to prevent
any meddling by unauthorized persons. Authorized staff should have access to download the data
from meters. Meters should also be equipped with facility for remote communication of data to the
controlling station for online analysis. Tamper proof arrangements should be available in the
meters. All accessible points for data transfer (serial ports, modems remote communication ports
etc) shall have provision for sealing by authorized persons.
The regular testing and periodical checks on specific complaints were attended by M&P staff and
readings are downloaded by authorized maintenance staff. The random check on the entire metering
system and the condition may be necessary, to ensure regular attention to the metering system to
prevent any leakages. This counter check may be carried out by a neutral agency such as quality
control unit or an independent third party.
Various checks and cross checks to be made by the independent team are as follows-
 Input/output cable terminals should be tight.
 Check for type (Electronic/Electro-mechanical) &accuracy class of meters.
 Check for any cut/puncture in service cable.
 Service cable from LT network to meter shall be properly clamped on pole using cleat
and shall not be hanging/lose.
 Consumer cable should be at adequate height, while crossing the street/road.
 Check for foolproof arrangement of the MCCB.
 Height of meter shall be adequate, so that reading can be visible properly while standing
in front of the meter.
 The total No. of meters, at one pole shall not be more than 8.
 The seals of the meter should be properly checked and there should be no visible cut
mark on any of the seals.
 Check for the proper earthing of the system, meter metal body and structures of
metering equipment.
Page 161 of 333

 Check that no wire (shunt) being inserted at the test terminal block (TTB).
 Record the due date for testing of the meters (as per periodicity/frequency) and the
actual date on which it was done, Also conformity of test results to standards &
regulation shall be checked.
 Cross check the working and errors of meters installed at site.
 Check of the Maximum Contract Demand of the consumer and MDI recorded by
consumer’s meter.
 Meter & Meter Box (MCCB) should be tightly fixed.
 Check that all required information must be written on meter box using a permanent
marker.
After physical inspection, reports will be prepared covering all aspects and the remarks will be
communicated to the concerned.
Booking of cases for tampering meters with assistance of Anti Power Theft Squad (APTS):
Vigilance team should be authorized to book cases on the consumers with the assistance of APTS in
case any fraud like tampering the meters, deviation of agreement conditions etc. will be detected.
Check List/Annexure-LT Metering & Service Cable
Page 162 of 333

LT FEEDER PILLAR
Introduction
LT Feeder Pillar meticulously designed to provide higher safety, reliability and protection with due
consideration of aesthetic features. It is an outdoor type four way L. T. distribution pillar which is
suitable for 3 phase 50 HZ 440V AC system. The Pillar is made of finest quality steel sheet which
is vermin proof and adequately ventilated.
The feeder pillar box contains double door, both front and back side of LT feeder pillar box having
fully detachable solid hinges allowing 180 degree opening and secured by a chrome plated door
handle with tamper proof lock facility including lock. Both front and back side shall be capable of
opening with panel key.
Feeder pillar are designed to take care of all cabling arrangements through suitable cable clamps.
The bottom plate of pillars are easy to detachable and provide knock out holes for entering different
sizes of the cables as per requirement at site.
Junction Box should be used for different service cables at LT poles. These Junction box should be
directly connected from feeder pillar outgoing Cable and the Cable should be routed properly using
cleat and clamps. Mouth of end termination of the rising cable should be kept in such a way that
rain water shall not enter inside the cable i.e. the open mouth should be in downward direction to
avoid any damage to cable. Proper thimbles size shall be used for joining the end of cable to
junction box.
Precaution
1. Only skilled or instructed personnel with relevant technical knowledge and experience, who are
also familiar with the safety procedures required when dealing with modern electrical/electronic
equipment are to be allowed to use and/or work on the equipment. All work shall be performed
in accordance with the Electricity at Work Regulations 2005.
2. The equipment must be disconnected/isolated from the incoming power supply before removing
any protective covers or working on any part from which the protective covers have been
removed.
3. Before any maintenance work is carried out, the mains supply to the equipment must be
isolated/switched off.
4. All equipment of conductive material installed in these pillars must be grounded, unless double
insulated or access to it is restricted to use of a tool.
Page 163 of 333

5. Any power tool must be regularly inspected and tested.
6. Any employee working on site must wear the appropriate protective clothing, e.g. reflective
vests, etc.
Check List
 Panel Body of feeder pillar must be checked for any leakage of current before
touching/operating.
 The 2 Nos. earth terminals at bottom of the feeder pillar should be properly earthed.
 All the service cables has to be inserted/passed through bottom of feeder pillar and no
service cable shall be passed through any of the door. It will prevent the closing of the
feeder pillar door.
 No cable/part of cable should be visible hanging out from feeder pillar.
 Checking of Proper size of lugs/thimbles used.
 Checking of tightening of incoming and outgoing feeder cables.
Check List /Annexure-LT Feeder Pillar
Page 164 of 333

LT FUSE BOARD
Introduction
LT fuse board shall be installed on One Pole for Plinth/Pole Mounted DT/H-Pole of the ratings
required at site. Insulated cable from LV side of DTs shall be connected to one side of fuse board
through proper size lug/thimble.
The arrangement and dimensions shall be as per the drawing below (all dimensions are in MM)-
Detail of Materials used in above Fuse Board
S. No. BOQ for Fuse Board QTY
1 Aluminum Bus Bar 6
2 Bakelite Support Insulator 6
3 Bakelite Sheet 1
4 Nut Bolts (10X50) 18
Page 165 of 333

Melting points of various metals
The melting point of various metals are given in table below-
Current Rating of Fuse wire
Copper Fuse wire
Page 166 of 333

Tinned Copper Fuse wire
Page 167 of 333

DT wise Connecting cable Rating
S. No. Transformer Rating Cable Size
2 no x 1C x 630 Sq mm, Al, XLPE

1 1000 KVA
Cable
2 630 kVA 1 no x 1C x 630 Sq mm, Al, XLPE
3 400 kVA 3 ½ C x 400 Sq mm, Al, XLPE
7 63 KVA 3 ½ C x 50 Sq mm, Al, XLPE
8 25 KVA 3 ½ C x 25 Sq mm, Al, XLPE
Check List
 LV cable from DT bushing shall be routed through thimble/bi-metallic clamp.

 Insulated cable from DT bushing to fuse board shall pass through DT meter CTs rings.
 Only insulated cable shall be used for connecting LV side of transformer to fuse board.
 Laying of cable from LV side of DT to fuse board shall be separated using cleat
(wooden/PVC).
 Proper size thimbles/Lugs should be used at cable end to join the cable to fuse board.
 Lugs/Thimbles shall be fixed by using proper size crimping tool (hammering of
Lugs/Thimbles must be avoided because this leads to weakening/breaking of strands of
cable).
 Proper color tapes should be used for taping at lugs/thimbles.
 Fuse Board shall be installed on Bakelite sheet.
 Check for tightness of fuse wire.
 Check for prevention of any oil & dust from fuse wire and aluminum parts.
 Height of fuse board shall be of minimum 6 feet.
 Only insulated cable shall be used for connecting fuse board to feeder line.
 Laying of insulated cable from fuse board to feeder line shall be properly routed using
clamps to fix it from hanging.
 Two number LT circuits may be provided on DT up to 100 kVA. 3 to 4 circuits to be
provided on DT of 200 kVA & above DTs
Check-list/Annexure- LT Fuse Board
Page 168 of 333

RECOMMENDATIONS
1. Regular Trainings/Seminars shall be organized for field staffs as a part of
policy for improving the capabilities for maintenance of distribution network.
2. Frequently breakdown of feeders shall be thoroughly checked for analyzing the
reason of fault and action shall be taken for minimizing the breakdown.
3. JE/SDO should maintain the Log Book of breakdowns in his area and all the
details of breakdowns must be recorded.
4. Phase balancing of feeders shall be regularly carried out as the balanced
distribution network have less interruptions, no heating of any one conductor
and ageing/breaking of conductors shall be minimized. A balanced network
has less technical losses than an un-balanced network.
5. Analysis of weak and strong area of every sub-division on the basis of data
recorded in Log Book, shall be carried out. After ascertaining the reason of
weak area, action should be taken to make it a strong area.
6. Reasons should be identified for frequent breakdowns of following equipments
and immediate action should be taken: -
 Distribution Transformers
 Line conductors
 U/G cables
 Jumpers
 Insulators
 Overloading of any feeder
7. Tree trimming shall be done on regular basis and the same should be taken as a
preventive maintenance.
Page 169 of 333

Diagnosis of LD
System andRemedial
Measures for
attending /
minimizing Faults
Page 170 of 333

Various Faults / Point of concern with Probable Causes
and Remedial Actions
Probable Cause of Fault / Point

S. No. Fault / Point of Concern Remedial Action
of Concern
1. Plan for Flashed /Punctured
or broken insulators
checking and replacement.
1. Flashed /Punctured or 2. Plan for Jumper Repairing,
broken insulators either of same conductor
2. Damaged jumper/Conductor size or next higher size of
3. Fault due to Tree Contact conductor size.
Overhead Conductor
1 4. Faults due to Birds 3. Plan for Tree Pruning /
Faults
5. Fault due to Cracked Pole Trimming by using Tree
6. Improper Earthing pruner instrument.
7. Unwanted wire b/w two 4. Plan to reduce Faults due to
phase Birds by installing bird
repellent/ falpper .
5. Proper Earthing should be
done
1. Plan to minimize insulation
failure by using proper
meggering instead of Hi-pot,
By usage of HS tape & end
1. Insulation Degradation caps to prevent from
i. Electrical Stress moisture.
ii. Mechanical Stress 2. Plan to reduce joint failures
Under Ground Cable
2 iii. Thermal Stress by not using sub-standard
Faults
2. External damage joints kits, by
i. Water Ingression qualified/skilled jointers.
ii. Joint Failures 3. Plan to reduce external
damage by proper patrolling.
4. Plan to reduce burning of
cables by proper load
balancing.
1. Defective Bushing: HV/LV 1. HT and LT connections
& Oil Leakage should be tight
2. Condition of Breather & 2. Proactive thermo-scanning
Distribution Transformer
3 Conservator 3. Earth value should be
Trippings / Interruptions
3. High unbalancing current checked during Planned
4. Continuous overloading of shutdown &earthing
DT connections should be
Page 171 of 333

of Concern
5. Frequent LT cable faults tightened
6. Improper protection of both 4. Earthing checked and
HT and LT side provided new earthing
7. Development of hot spots where ever required.
due to passage of time 5. Proactive patrolling, Drain
8. Poor/defective earthing of valves should be sealed
neutral & body of DT and Segregate multiple LT
of LT feeders feeders that feed from one
9. Birds / Animal ACB.
electrocution 6. Top fence covering in
10. Poor maintenance of DT monkey/domestic animal
11. High rating fuse used prone s/s, provision of HT
insulation caps.
7. Overhauling of the
DT/replacement with
new/repaired one.
Differential Protection
operation
1. Inter-turn fault/ Aging
2. LT joints & HT bushing 1. Complete visual Inspection
failures of power transformer.
Power transformer 3. Short circuit at in-zone of 2. Rectifying the root cause of
4
Tripping both sides CTs. breakdown
4. IED Failure 3. Stability test of power
5. CTs wiring problem transformer.
6. CT Saturation
7. Fault at cable box before
LV
1. High temperature of oil due 1. Checking of OTI meter &
to heavy loading. WTI meter for variation.
Oil temperature
5 2. Relay mal-function. 2. Check loading condition
indicator tripping / alarm
3. Low intensity Inter turn 3. Winding resistance of power
fault. transformer.
1. High temperature of
1. Checking of OTI meter &
winding due to heavy
WTI meter for variation
Winding temperature loading.
6 2. Check loading
indicator tripping /alarm 2. Relay mal-function.
3. Winding resistance of power
3. Low intensity Inter turn
transformer.
fault.
1. Due to fault in 11 Bus 1. Checking of tripping of any
system. outgoing feeder along with
7 11 KV incomer tripping
2. Fault near to substation or intensity of fault
very high intensity of fault. 2. Check breaker timing of
Page 172 of 333

of Concern
3. High breaker timer of tripped breaker.
outgoing breaker
1. Check Relay’s tripping
1. Due to over loading.
11 KV outgoing breaker parameters for analysis.
8 2. Due to phase fault /earth
tripping 2. Line inspection is required
fault
before again charging.
1. Due to heavy voltage
Failure of Lighting 1. Replace the faulty LA.
9 fluctuation.
arrestor 2. Check other installed LAs.
2. Aging of lighting arrestors
1. Due to charging problem.
Low voltage at DC 1. Check charger at location.
10 2. Battery issues in existing
system 2. Impedance test of battery
system.
Earthing of any one of the Isolate DC supply at every
terminal with ground it maysection and check DC leakage
11 DC leakage at substation
occur at yard's equipment of in
in system and rectified the
VCBs same.
1. Check earthing resistance at
every pit of yards & neutral
of transformer.
Poor earthing at grid Due to aging / Soil condition
12 2. In case of poor earthing go
substation & improper installation
for parallel earthing concept
and connect it with old
earthing PIT.
Page 173 of 333

Distribution
System
Transformers Circuits
Under Over Head

Distribution Power Ground
Transformers Transformers Circuits
Circuits
Aerial Bunched Bare Insulated

Cable (ABC) Conductor Conductor
Page 174 of 333

Distribution
Transformers
Page 175 of 333

Probable Causes of DT failure and Measures
Loose
connection
both at HT
& LT side
Bird / Animal Hot Spots
Electrocution due to
passage of
time
Probable
Cause of Poor/
defective
Low BDV / DT failure earthing -
IR value neutral &
DT
Low oil level Poor/

due to defective
Leakage / earthing of LT
Pilferage feeders
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High
Unbalancing
Current
Tampering by Continuous
Miscreants Overloading of
DT
Probable
Cause of
DT failure
Poor
Maintenance Frequent LT
of DT Cable Faults
Improper
Protection of
both HT and
LT side
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Measure
HT and LT connections should be tight
Proactive thermo-scanning and accordingly Corrective

action and Preventive Action (CAPA)
Earth value should be checked during Outages /

Shutdowns & earthing connections should be tightened
Earthing checked and provided new earthing whereever

required.
Proactive patrolling, Drain valves should be sealed
Segregate multiple LT feeders that feed from one ACB

/MCCB / Fuse Board
Top fence covering in monkey/domestic animal prone

S/S, provision of HT insulation caps
Overhauling of the DT/replacement with new/repaired

one
Page 178 of 333

Measure
Monthly load recording & balancing of load on DT & LT feeders.

UBC should not exceed 10% of Full Load/ Running Load
Load transfer to nearby DT/ augment or swap DT/ provide

additional DT
Replace sick cables and reduce length of LT feeders
Tree trimming to avoid transient faults.
Install Appropriate rating of fuse on HT & LT Side of DT in case of

breaker installed get relay setting checked through M&P
Proper maintenance must be done & defective LT ACBs / MCCBs /

Fuse board / other parts must be Replaced as & when required
Segregate multiple LT feeders that feed from one ACB /MCCB /

Fuse Board
Pre inspection of scope of work, Ensure proper maintenance using

proper tools & attention to all the accessories
More proactive patrolling both by security team and Maintenance

team
Page 179 of 333

Distribution transformer failure analysis & corrective
actions.
1. Defective Bushing: HV/LV & Oil Leakage

Cracked & spotted HV/LV bushing fails to provide appropriate insulation. Also continuous oil
leakage & seepage may cause DT failure due to no cooling & proper insulation of windings.
Improper Connections at Bushing of Transformers
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Page 181 of 333
Oil Leakage at Drain Valve
CORRECTIVE ACTION & PREVENTIVE ACTION:

Check bushings for cracks, chippings, over heating marks, flashover marks, replace the effected
bushing.
 Oil leakages if any then keep an eye on
a. tightness of nuts
b. tightness of oil seal caps/replace oil seal & gasket if required
 Don’t apply M-seal or other material on HV/LV bushing to stop oil leakage as this may
causing flashover.
 Check the HT/LT rod and replace if required.
OIL LEAKAGE FROM TOP PLATE
 Oil leakage from top plate can be attended by tightening nuts & bolts diagonally
 Replace gasket if required.
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2. Condition of Breather & Conservator
Poor condition of breather like cracks on its body, improper coupling of Cup, absence of oil in
cup cause rust formed due to moisture ingress through breather
Page 183 of 333

OIL LEVEL
OIL LEVEL
Breather missing / not installed
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Damaged Explosion vent & Moisturized Silica Gel in Breather
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Damaged Explosion vent
BREATHER
 Moisturized (Pink) Silica gel should be replaced with new / re activated (blue) Silica Gel.
 In case of new Breather, ensure to remove seal from breathing hole of oil cup.
 Re-activation of used silica gel to avoid excessive consumptions
 After filling silica gel, Breather should be tight properly.
 Pour oil in Breather oil cup, if required.
 Breather should be tightly fixed to breather pipe.
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 Due to improper coupling of breather bottle and flange, breathing points may be formed,
thereby creating a passage for moisture, which leads to condensation and rusting of the
conservator tank from inside.
 During maintenance , the breather size and type to be checked & non transparent breather
should be replaced by transparent breather of recommended size as below:
 < 400 KVA- 0.5 Kg

 > 400 -990 KVA- 1 Kg
CONSERVATOR & OIL
 Oil sample for BDV test should be taken in proper oil sample bottle. In case of low BDV
value take necessary action.
 Check the cap and surface of conservator tank for rusting/holes.
 Check oil level from oil gauge.
 Oil topping should be done if required.
 Check Oil Gauge for leakage.
Explosion Vent Diaphragm
 Check the Diaphragm, if it is torn then replace it by a new one
3. High unbalancing current :
Higher unbalance current cause rise in winding temperature. This overheating of winding may
damage the inter-winding insulation level and so as to distribution transformer failure.
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 Monthly load recording and balancing of DT as well as LT feeders.

 Unbalance Current should not exceed 10% of Full Load/ Running Load.
4. Continuous overloading of DT
Distribution Transformers are generally not recommended for continuous overloading. However
overloading for a short duration cannot be avoided. It is one of the prime responsibilities of the
utilities to keep a check on the loading of a transformer and should record the loading Patton on a
Page 189 of 333

history card. In case of overloading the additional loss generates more heat, which effects the
burning of winding insulation, causing ultimate failure of the transformer.
 Transfer the load to nearby DT (If possible)

 Augment or swap the overloaded DT
 Provide additional DT.
5. Frequent LT cable faults
More the cable faults, more the fault current travels towards the transformer.
 Replace sick cables and reduce length of LT feeders
 Tree trimming should be done to avoid transient faults.
Page 190 of 333

6. Improper protection of both HT and LT side
Improper protection system always invites the risk of damage of equipment. As Distribution
Transformers are one of Costliest & vital part of Distribution System, Special care must be
taken while selecting switching & protecting devices. Preferably at HT Side Ring Main unit
(RMU) / breaker should be used with appropriate Protective Relays in case of small DTs Drop
down Fuses (DD fuses) of appropriate ratings can also be used. At LT Side of Distribution
Transformers Appropriate rating of ACBs / MCCBs can be used.
In case of absence of proper protecting devices or installation of improper Rating / Size of fuses
the risk of DT failure became very high. This could be the due to:
 Installation of RMU / Breakers with defective / inappropriate Relay or relay setting
 Installation of inappropriate Rating / Size of fuses
 Consistent overloading.
 Lightning Arrestors (LAs) are not installed.
 Inappropriate Earthing of DT / Neutral / Las
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Installation of inappropriate Rating / Size of fuses
Page 195 of 333

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Page 197 of 333

 Get relay setting checked from M&P department
 replace defective LT Fuse Board/ LT ACB
 Segregate multiple LT feeders that feed from one LT fuse Board
7. Development of hot spots due to passage of time

Development of Hot spots in the system are mainly due to Loose nut bolt connection at HT/LT side,
Improper Lugs crimping, underrated wires & nut bolts, improper alignment of blades of G.O switch,
loose binding of conductor etc . Prolonged Hot spots causes breakdown the system which further
loss of reliability & revenue. Also it will make the equipment deteriorated day by day.
 HT and LT connections should be tight.

 Proper size of lugs & nut bolts should be used.
 Proactive thermo-scanning and urgent compliance to the observations should be done.
 Proper crimping of lugs should be carried out. Minimum 3-4 crimping required for each
lugs
Page 198 of 333

8. Poor/defective earthing of neutral & body of DT and of LT
feeders
In electricity supply systems, an earthing system or grounding system is circuitry which connects
parts of the electric circuit with the ground, thus defining the electric potential of the conductors
relative to the Earth's conductive surface.
Poor earthing of neutral will not allowed to pass the fault/ unbalance current though the ground.
 Check earthing of DT neutral & body, Fence, LT/HT frames.

 Earth resistance values must be below 1Ω. If the test values are greater than 1Ω, then new
earthing must be provided as soon as possible.
 Proper earthing of LT feeder should be checked & provided new earthings where ever
required.
 Total 5 earthings should exist in pole mount DT.
 2 for DT neutral
 1 body & fence for DT
 2 for LA.
Earth value should be checked during planned shut down and earthing connections should be
tightened.
9. Cat/monkey electrocution
In many case, unnecessary trippings and DT bushings failures noticed due to Cat/ Monkey/ Birds
electrocution.
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 Top covering of fence of monkey/domestic animal prone substation.

 Provision of HT insulation caps
Top covering of fence of monkey/domestic animal prone substation
Page 200 of 333

10. Poor maintenance of DT
Transformer failure can also stem from poor O&M practices. For example, in addition to normal full
load, continuous over-heating and higher no-load losses may reduce the life of the transformer due to
reduction in the life of insulating papers, oil, etc. Other improper O&M practices leading to
transformer failure are mentioned below:
 Negligence to Low BDV value of oil .

 Negligence to Megger process & its results.
 Low oil level.
 Non-usage of Cleats at HT & LT sides.
 Poor handling of LT cables associated with DT LT side.
 Negligence to HV/LV connection
 Pre inspection of scope of work to ensure less down time of PSD and material
requirement.
 Proper LT Cable end terminations to be installed in order to prevent it from ingression of
water during to rains which turns in Cable fault. ( see Pics below)
Cable end termination
Cable end termination
Faulty LTCable end TerminationNewLTCable end Termination
Page 201 of 333

 IR Value Test
Check the IR value of the DT:
 HT to LT; Min. value = 100 MΩ

 HT to earth; Min. value = 100 MΩ
For testing of above values should HT insulation tester should be set at 5000 V
 LT to earth; Min. value =50 MΩ
For testing of above values should LT insulation tester should be set at 500 V
If the IR values are lower than 100 MΩ, then the DT should be sent to the transformer
workshop.
*Note: However, DT can function at IR value of 10 MΩ, but chances of failure increase for
Page 202 of 333

such DT.
 LV/HV CONNECTION (Palm Connectors)
 Nuts, bolts & clamps of H.V. & L.V. connections should be tight.
 Proper size of lugs should be used on LV/HV cable as to maintain proper voltage.
 Defected palm connectors should be replaced. (Pitting on the surface causes HOT
SPOT)
 Check HT & LT cable cleats to avoid mechanical stress on transformer bushing.
 LT leads & Neutral earth wire should not touch radiators.
 During the maintenance palm & lug contact surface to be cleaned properly and
petroleum jelly to be applied to avoid rusting and hot-spots.
 Earthing
 Check earting of DT Neutral & body ,LTACB, fencing LT/HT
Page 203 of 333

Page 204 of 333
Power
Transformers
Page 205 of 333

Probable Causes of Power Transformers failure and Measures
Interturn
fault/ Aging
Fault at cable
box before LT joints &
LV HT bushing
failures
Probable
Cause of
Faults in
Power Short circuit
CT at inzone of
Saturation Transformers both sides
CTs.
CTs wiring IED

problem FAILURE
Page 206 of 333

Bushing
failure
Heavy fault Gases

near to Sub generation
Station on Buchholz
Probable
Cause of
Faults in
WTI & OTI Power Anomaly in
relays Transformers on load tap
operation changer .
Low Insulation
intensity failure &
incipient core
faults shorting
Page 207 of 333

Measure
Visual inspection of transformer , current transformers ,
bushings & cable end joints etc.
Complete testing of power transformers
Negligence Routine maintanance of transformer
Exposed LT bus-bar with-out insulated paint or sleeve
Routine checks of IED healthiness
Over loading on transformer & cables
CT testing on routine basis
Poor earting at neutral point
Large no of OLTC operations
Frequent high intensity faults
Poor neutral earthing
Page 208 of 333

EFFECTS OF BREAKDOWN / TRANSFORMER FAILURE
INTER-TURN FAULTS
Page 209 of 333

RODENT ENTRY IN INCOMER BREAKER CAUSE TANSFORMER
BREAKDOWN
INCOMER CABLE FAILURE
Page 210 of 333

Best practices at substation level maintenance
 Note down the temperature and record the maximum daily ambient temperature.
 Check that temp rise is reasonable. In case of any abnormal variation, check the cooling
system of T/F. If the same is not found in order. Shut down the T/F for further
investigation.
 Check against transformer oil level/ temperature. Top up with dry oil, if necessary.
 Check for any oil leakage.
 Check for any abnormal sound or excessive chattering. Shut down the T/F in case of
abnormal noise, for further investigation
 Examine relays and alarm contacts and their operation, fuses etc. Check for relays
functioning clean or replace the contacts if required
 Measure earth resistance of the (a) T/F body, neutral and other body parts, (b) Keep
proper record of test results. (Earth testing to be done during driest part of the season)
 Examine Firefighting equipments and ensure that these are in order.
 In case of bushing -Test oil for dielectric strength Dehydrate or replace the oil, if
necessary.
 Use LT sleeve on 11 KV side
Earthing of panels
Page 211 of 333

 In case of cooler fan & pump bearing all Lubricate bearings, check gear box. Examine
Contacts, Check Manual control and interlocks. Replace burnt or worn out contacts or
other parts.
 I.R. values with 2.5KV rating meggar. Convert it at 700 C and compare the values with
the value taken at the time of commissioning.
 Earth resistance of the (a) T/F body, neutral and other body parts, Keep proper record of
test results. (Earth testing to be done during driest part of the season)
 Avoid leakage/seepage of oil from main tank to OLTC tank.
 Continuously monitoring of DGA test to keep close eye on transformer condition.
 To reduce eddy current, proper earthing of transformer body top cover with body is
must.
Page 212 of 333

Page 213 of 333
DO’s & DON’T’s for Power Transformers
DO’s
1. Ensure leveling of Transformer at the time of installation.
2. Ensure Buchholz & OTI / WTI are unlocked (in service position) before energizing the
transformer.
3. Fill transformer oil in the OTI / WTI pockets before fixing the temperature sensing bulbs
in the pocket.
4. Check air cell / bellow in conservator.
5. Ensure the mounting inclination of Buchholz relay (3-50) .Provide the suitable support if
the connecting pipe is too long to avoid false tripping of transformer on Buchholz.
6. Check operation of Buchholz relay by draining oil or injecting air as the case may be.
Adjust the floats & mercury switches if required.
7. Ensure Fire wall between the two transformers as per requirement.
8. Check Fire extinguisher / emulsifier system for protection of transformers.
9. Ensure earthing of transformer fence for safety of human being.
10. Ensure proper earth of transformer neutral as well as body as per ISS standard.
11. Ensure the radiator valves are open.
12. Charge the transformer at normal Tap with all protection in service.
13. Do ensure TAP position indicated by TPI with OLTC are matching.
14. Ensure phase marking as specified in the rating plate.
15. Check the oil level in Transformer main tank, bushings & OLTC as a routine practice
and maintain up to the marked level.
16. Bleed air pockets before energizing the transformer.
17. Always use filtered dry oil confirming to ISS 335 to top up the conservator if required.
Check BDV of oil used for top up (with minimum BDV-60 kV). Oil drum to be filtered
separately before filling oil in the transformer.
18. Check the oil for moisture contents (ppm), acidity & sludge as per ISS 1866.
19. Check the oil level in the silica gel breather oil cup and ensure that air passages are free
in the breather. Top up oil up to the mark if required.
20. Inspect the transformer, radiators, bushings, connected oil pipes for any oil leakage and
attend it immediately.
21. Attend the leakages on the bushing immediately.
22. Examine the bushings for dirt, deposits and coats and clean them periodically.
23. Provide adequate protection system for the transformer w.r.t its rated capacity.
24. Check protection circuit periodically.
25. Use appropriate size of fuse as per the rating of the distribution transformer.
26. Check & clean the relay alarm & trip contacts. Perform trip test.
27. Ensure WTI / OTI / PRV / PRD / MOG (oil level) gauges are in working condition with
free movement.
28. Ensure calibration of the temperature gauges / RTD’s / temperature sensors.
Page 214 of 333

29. Ensure OTI / WTI alarm / Trip settings as per our standard philosophy or as specified by
the OEM.
30. Reduce the load immediately if OTI/WTI temperature goes beyond 80/90 0C
31. Ensure cleanliness of TB’s for moisture & dust deposits to avoid tripping of transformer
due to dc leakage.
32. Check and thoroughly investigate the transformer whenever any alarm or transformer
protection is operated. Don’t take such alarms for guaranteed as false / fictitious ones.
33. Ensure all the control & protection supplies are switched “ON” before energizing the
transformer after routine maintenance / shut downs / break downs.
34. Ensure all the transformer auxiliaries protection relays as operated are reset before
energizing the transformer.
35. Carry out maintenance of diverter switch (OLTC) as per schedule or earlier if number of
tap operation exceeds the limit as specified by the OEM.
36. Examine & replace burnt and worn out contacts as per schedule of the diverter switch.
37. Check all bearings & operating mechanism and lubricate them as per schedule.
38. Check the gear box level, if less, top up with specified oil.
39. Remove the air vent plug of diverter switch before energizing the transformer.
40. Open the equalizing valve between tank & the OLTC where ever provided at the time of
filling the oil level in the tank.
41. Close the equalizing valve between tank & the OLTC during operation.
42. Inspect painting and if necessary, retouching should be done.
43. If any inspection cover is opened or any gasket joints are to be tightened, then tighten
the bolts evenly to avoid uneven pressure.
44. Check the diaphragm of relief vent (if provided), if crack or broken, replace it.
45. Clean the HT & LT bushings and terminations before recording IR value of the
transformer.
46. Record IR value of the transformer independent of connected cables & LA’s etc.
47. Record IR value of transformer w.r.t Oil / Winding / Ambient temperature and compare
the values with the previous one after converting to same temperature. Record IR value
of each winding with other winding earthed.
48. Get the oil checked for DGA annually.
49. Carry out thermo scanning of transformer for internal hotspots once in six months and
correlate with DGA analysis. Attend immediately if detected.
50. Maintain records for factory & field test reports for comparison in future.
51. Connect gas cylinder with automatic regulator if transformer is to be stored for long, in
order to maintain positive pressure.
52. Fill the oil in the transformer at the earliest opportunity at site and follow storage
instructions.
53. Check the door seals of marshalling Box. Change the rubber lining if required.
54. Equalize the diverter compartment .of the OLTC by connecting equalizing pipe between
flange joints provided on the tap changer head
Page 215 of 333

55. After useful life of equipment or during service, constituent material and transformer oil
should be disposed ‘off /handled in environment friendly way in compliance to
applicable regulations.
56. Cover the naked cable terminations with HT insulation Tape.
57. Ensure arcing horn gap as per IE rules (in case provided).
58. Keep tap changer links for all the three phases for dry type transformer in the same
position.
59. Ensure clean environment near the transformers.
60. Avoid oil spillage near the transformer.
61. Always take oil sample for testing from the sampling valve as per procedure laid in the
ISS specification.
DONT’s
1. Do not energize transformer without thorough investigations, whenever any alarm or

protection is operated.
2. Do not re-energize the transformer unless Buchholz’s gas is analyzed.
3. In case tripping of transformer through differential & REF protection, the vicinity of
transformer should be explored for any visible fault viz. cable, termination, bird age ,
kite, wires , cracks etc. The transformer should also be tested before energizing. Test
results must be comparable with the previous test results.
4. Do not handle the off circuit Tap switch, when the transformer is energized.
5. Do not energize transformer unless off circuit tap switch is in off position.
6. Do not leave off circuit tap switch unlocked.
7. Do not overload the transformer other than the specified limits as per ISS 6600.
8. Avoid unbalance load on the transformers.
9. Avoid frequent short circuit test specifically for distribution transformers to avoid undue
stresses.
10. Do not allow conservator oil level to fall below ¼ level increase beyond 2/3 level.
11. Do not mix the oil unless it confirms fully to ISS 335.
12. Do not allow inferior oil to continue in transformer.
13. Do follow ISS 10028 for various checks & routine maintenance.
14. Do not allow unauthorized entry near the transformer.
15. Do not allow dirt & deposits on the bushings.
16. Do not meddle with the protection circuit.
17. Do not leave the M kiosk open.
18. Do not switch off space heater in M.Kiosk.
19. Do not move the transformer with bushings mounted.
20. Do not use low capacity lifting jacks on transformer for jacking.
21. Do not change the settings of OTI / WTI too frequently.
22. Do not leave the red pointer of OTI / WTI behind the black pointer.
Page 216 of 333

23. Do not leave any connection loose.
24. Do not continue with pink silica gel.
25. Do not over tighten any of the gaskets.
26. Do not leave secondary terminals of unloaded CT open.
27. Do not commission the transformer with low IR value.
28. Do not continue to run the transformer with relief vent diaphragm broken or cracked.
29. Do not store transformer for long, should be erected & commissioned at the earliest.
30. Do not keep the transformer gas filled at site for long period.
31. Do not leave tertiary terminals unprotected outside the tank. Connect them to tertiary
LA’s protection scheme when connected to load.
32. Do not bend capillaries of OTI / WTI thermometers beyond its permissible limits
(approx. 100 mm dia ).
33. Do not allow WTI / OTI temperatures to exceed 70 0C during dry out of the transformer
and filter machine temperature beyond 75 0C.
34. Do not parallel the transformers which do not fulfill the condition for paralleling.
35. Do not leave ladder unlocked, when transformer is in service , in case it is provided.
36. Do not change the sequence of valve opening for taking standby pump and motor into
circuit.
37. Do not switch on water pump unless the oil pump is switched on.
38. Do not switch on water pump unless the oil pump is switched on in case of water cooled
oil coolers.
39. Do not allow water pressure more than oil pressure in differential pressure gauge in
case of water cooled oil coolers
40. Do not use fibrous cloth, jute, cotton to clean the transformer inside parts, bushings &
valves etc.
41. Do not use naked light inside the transformer tank, may cause hazardous fire &
accidents.
42. Never use loose tools while working through inspection window. Keep your pockets
empty.
43. Do not expose core & winding of the transformer to atmosphere for longer period.
44. Do not run transformers in auto mode in case AVR is faulty.
45. Do not top up oil in rainy season / moist or cloudy weather.
46. Do not open inspection window during rainy season / moist or cloudy weather.
47. Do not carry out ac tests after dc tests on the transformer, will give erroneous results.
48. Do not forget to provide oil sump/ soak pit for drainage of oil in case of eventuality.
49. Do not leave Tan δ point unearthed.
50. Do not climb on charged transformer.
51. Never run transformer with abnormal sound.
52. Never open the doors of dry type transformer while in service.
53. Do not subject the transformer to vacuum with bushings installed.
54. Never carry out welding on the transformer body / radiator etc. carrying oil.
Page 217 of 333

Battery Bank
Page 218 of 333

Probable Causes of DC failure and Measures
Basic defects observed at battery bank
1. Low voltage at output terminals.

2. DC-leakage at grid level.
3. DC-failure at grid substation.
CHECKING THE HEALTHINESS OF BATTERY CHARGER PROCEDURE
 “SWITCH OFF” The battery charger, so that load is directly connected to the battery.
 Observe load voltage for at least 15-20 minutes. It should not drop beyond rated
voltage.
 The “DC UNDER VOLTAGE” And “AC MAINS FAIL” Alarms should operate.
 “SWITCH ON” The battery charger. Initially the battery will draw a high current limited
to the maximum rating of the charger and then gradually reduce to the normal value.
 During this process none of the fuses should blow.
 After the current reaches normal value, reset the “DC UNDER VOLTAGE” Fault.
 Check the “ANNUNCIATION CIRCUIT” by manually shorting the fault contacts.
In case of separate float and boost charger, check the interlocking between “DC
CONTACTOR” (which connects the battery to float charger) and “AC CONTACTOR” of
charger.
 Check operation of “EARTH FAULT RELAY” by temporarily grounding the +ve or –ve
terminal through a high resistance
Page 219 of 333

Best practices
 Checking specific gravity and voltage of each cell of lead acid cells. (Before and after
charging) (Weekly when trickle charge exists)
 Perform leakage test by lamp or voltmeter method.
 separators remain in place and are keeping the plates properly spaced (in case of
transparent containers only)
 Enough distilled water and acid are kept in storage to meet current needs. Check
containers for cleanliness.
 All connections of charger and battery for tightness.
 Metallic structures / parts located in the room for corrosion and clean and paint as
necessary, check ventilation system fan etc. for proper operation to make sure that no
explosive gases are being accumulated in the battery room due to excessive gassing or
poor ventilation.
Page 220 of 333

Over View of Distribution Lines
Distribution
Lines
Underground Over Head

Circuit Circuit
Aerial
Bare Insulated
Bunched Cable
Conductor Conductor
(ABC)
Page 221 of 333

Probable Causes of Underground Cables failure and
Measures
Electric
stress
Thermal Mechanical
Stress Stress
Probable
Cause of
Faults in
Cables
Joint
External Failure
Damage
Water
Ingress
Page 222 of 333

Measure
Plan to minimize insulation failure
Plan to reduce joint failures
Plan to reduce external damage
Plan to reduce burning of cables
Page 223 of 333

TYPES OF UNDERGROUND CABLE FAULTS
Cables are generally laid directly in the ground or in ducts in the underground distribution system.
For this reason, there are little chances of faults in underground cables. However, if a fault does
occur, it is difficult to locate and repair the fault because conductors are not visible. Nevertheless,
the following are the faults most likely to occur in underground cables:
1. Open-circuit fault
2. Short-circuit fault
3. Earth fault.
(i) Open-circuit fault.
When there is a break in the conductor of a cable, it is called open circuit fault. The open-circuit
fault can be checked by a megger. For this purpose, the three conductors of the 3-core cable at the
far end are shorted and earthed. Then resistance between each conductor and earth is measured by a
megger. The megger will indicate zero resistance in the circuit of the conductor that is not broken.
However, if the conductor is broken, the megger will indicate infinite resistance in its circuit.
(ii) Short-circuit fault.
When two conductors of a multi-core cable come in electrical contact with each other due to
insulation failure, it is called a short-circuit fault. Again, we can seek the help of a megger to check
this fault. For this purpose, the two terminals of the megger are connected to any two conductors. If
the megger gives zero reading, it indicates short-circuit fault between these conductors. The same
step is repeated for other conductors taking two at a time.
(iii) Earth fault.
When the conductor of a cable comes in contact with earth, it is called earth fault or ground fault.
To identify this fault, one terminal of the megger is connected to the conductor and the other
Page 224 of 333

terminal connected to earth. If the megger indicates zero reading, it means the conductor is earthed.
The same procedure is repeated for other conductors of the cable.
ROOT CAUSE OF FAILURE
Following are the main causes of Under Ground Cable failure.
1. Insulation Degradation
2. Joint Failure
1. Insulation Degradation
Causes of Insulation Degradation:
a) Electrical Stress:
Electrical stress is always present at the cable. The voltage applied at the three phases of a
cable is 120º apart. Due to this a rotating electrostatic field is produced. These electrostatic
field lines of force are perpendicular to the equipotential surface. That’s why electrical
stresses are there within the cable. These stresses increases due to the following factors:-
 Phase to Phase & Phase to earth clearance at cable termination are not proper.
 Core crossing above cut back area at cable termination.
 Untreated screen cut back during installation of cable termination.
So the above mentioned points should be taken care while making cable termination, to
reduce the stresses in the cable.
Page 225 of 333

Insulation screen Conductor Insulation
Insulation screen Conductor Insulation
In the Pic-1 it is shown that the temperature near the termination reaches to abnormal temperature
& thus the breakdown of the insulation takes place.
In the Pic-2 it is shown that how the electrical stresses vary from the closer of the cable core to the
outer sheath of the cable. Electrical stress is greater close to the core & slowly reduces as we move
away from the core to the outer sheath.
In the Pic-3 it is shown that while making joints in the cable mastic tape should be properly rapped
closer to the ferrule. Otherwise this also produces electrical stress on the cable.
b) Mechanical Stress:
The following reason produce Mechanical stresses on cable:-
 Improper bending radius.

 Mechanical vibrations.
 Improper cable supports.
Page 226 of 333

In the above picture it is shown that if the bending radius is not properly maintained within the
bend of a cable then that produces mechanical stress on the cable & this mechanical stress
produces localized heating i.e. thermal stress on the cable. Thus insulation breakdown take
place. So the bending radius should be properly maintained while there is a bend in the cable.
Sharp bending in the cable should be strictly avoided.
c) Thermal Stress:
The following reason produce Thermal stresses on cable:-
 Overloading.
 High thermal resistivity of soil.
 Improper electrical connections.
 Chemical Attack due to environmental contamination.
Page 227 of 333

PIC-1 PIC-2
PIC-1 PIC-2
Poor or Loose Earthing connection also causes Thermal stress
Above Pictures show how cable gets faulty due to thermal stresses. In the second picture it is
also clear that due to abnormal bending radius, thermal stresses take place within the cable &
ultimately produces breakdown of the cable insulation.
Due to Poor & loose earthing connection fault current will not be able to pass to the ground
quickly. It will travel through the core for little bit longer time & this will produce heating on
the cable i.e. thermal stresses will bethere within the cable. So, cable earthing should be
properly connected with the Sub-station (s/s) earthing& the S/S earthing should be solidly
grounded.
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d) Water Ingress.
PIC-1 PIC-2
Moisture in Cable conductor.Damage sheath is point of moisture ingress.
End caps / termination should be used.
PIC-2 in the above shows that if the outer sheath of the cable gets damaged then it will absorb
moisture from the atmosphere & the cable insulation gets deteriorated due to ingress of moisture.
So damaged outer sheath should be repaired & also while storing the cable, end caps should be
provided at both the ends of the cable. Otherwise moisture will enter through the cable ends.
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e) External Damage.
PIC-1
Insulation degradation close to fault

PIC-1point
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PIC-2
Insulation Failure due to External damage

PIC-2
In the 1st picture above it is shown that how cable gets damaged due to the unconsciousness of the
jointer. In this picture it is shown that the jointer is isolating the faulty joint box of the faulty cable
but due to his lack of conscious the blade of his cutting instrument touching another healthy cable in
the vicinity. That’s how the insulation of that healthy cable also gets damaged.
2nd picture shows another cable joint box which got damaged due to some digging activity. Due to
the fact that cable routes are not known to the outside digging agency, they are damaging our cable
insulation very frequently while they carry out digging for their own need.
2. Joint Failure
Joint Box failures are very frequent & common phenomena in cables. There Are Lots Of reasons
for which Joint Box failure occurs. Some of them are discussed below:-
a. Use of Moisture affected Cable:
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Moisture in conductor of cable causes more stress at connecting portion i.e. ferrule area which lead
to puncture the cable from same
Actually moisture gathering makes the path conducting. So moisture gathering tries to make a
conducting path between the core & the earth. Due to moisture ingress, leakage current flows
between the core & the earth. That’s why it gives unnecessary stress on the cable
b. Dry Paper Insulation (Occurs in Transition Joint Failure):
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Page 233 of 333
Dry paper insulation reduces dielectric strength of cable. Consequently more stress develops
over paper insulation at crotch portion which leads to cable puncture.
In case of transition joint Oil barricader should be used in the PILC side otherwise Oil will flow
from PILC side to the XLPE side through the joint box, which will leads to joint box failure.
Also XLPE & PILC side of the transition joint should be at the same level.
c. Poor Workmanship of the jointer:
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Wrong dimensions, irregular semiconductor & other errors caused various stress in joint during
service conditions & ultimately leads to failure of cable joint.
d. Use of Fillers instead of step-down ferrules:
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Sharp edges of fillers can damage joint body. Step-down ferrule must be used instead of fillers.
Filler must be used with extreme care after crimping in case of non-availability & extreme urgency
only.
While making joints between different cross section of cables like joints between 150 mm² to 240
mm², 240 mm² to 300 mm² etc. Step-down ferrule must be used instead of fillers. Filler must be
used with extreme care after crimping in case of non-availability of step down ferule or extreme
urgency only
e. Overloading (esp. in LT Cable joints)
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Overloading leads to localized thermal stress which reduces insulation strength at joints which
ultimately leads to joint failures.
f. Lack of standard Jointing Pit:
Lack of standard pit while jointing due to obstacles in vicinity causes mechanical stress in joints.
This in combination with moisture ingress leads to tracking path over insulation & ultimately leads
to insulation failure of joint.
g. Improper Support to Cables on pole
Suitable & proper Support must be provided to Cable when it needs to be connected with over
Headlines / Distribution Transformers.As due to improper support, cable end terminations have to
bear excessive pressure & weight of Cable and may lead to failure of Cable end termination.
Page 237 of 333

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Page 240 of 333
PREVENTIVE & CORRECTIVE ACTION PLAN
PREVENTIVE & CORRECTIVE ACTION PLAN

1. PLAN TO MINIMIZE INSULATION FAILURE
2. PLAN TO REDUCE JOINT FAILURES
3. PLAN TO REDUCE EXTERNAL DAMAGE
4. PLAN TO REDUCE BURNING OF CABLES
Details of all above points has been mentioned below:
1. PLAN TO MINIMIZE INSULATION FAILURE

 Pressure testing should be minimized by use of Fault Passage Indicator for faulty section
isolation &megger, instead of using Hi-POT in all successive sections.
 Cables to be stored & handled properly.
 To prevent moisture ingress heat shrink end caps should be used which are available in our
stores.
 Overloading of cable is to be avoided in any circumstances (especially in LT cables.)
 All the phases should be loaded evenly in LT cables.
 Cable earthing to be connected properly with substation Earthing.
2. PLAN TO REDUCE JOINT FAILURES
 Moisture affected cable should strictly be avoided during jointing. HS end caps should be
used for storage.
 Joints are to be made by qualified jointers.
 Good workmanship is to be maintained while jointing.
Page 241 of 333

 Only standard jointing kits are to be used.
 Cable should be energized only after epoxy compound is firmly set in case of 3M joints.
3. PLAN TO REDUCE EXTERNAL DAMAGE
 Proper depth of cable should be maintained as per standards

 Cable Route Should be properly mapped in GIS.
 Digging agency should inform the Sub-Division staff prior to digging & also should confirm
about the cable route before digging.
 Cable Route Map should be available to the Sub-Division staff such that they can provide
the same to the external agency before digging.
4. PLAN TO REDUCE BURNING OF CABLES
 Overloading of cable is to be avoided under any circumstances.

 Unbalance loading in three phases of cable should be avoided (in LT cables).
Page 242 of 333

Overhead
Circuits (O/H
Lines)
Page 243 of 333

Probable Causes of Overhead Lines Faults and Measures
Flashed
/Punctured
or broken
insulators
Improper Damaged
Earthing jumper/Co
nductor
Probable
Cause of
Faults in
O/H Lines
Fault due Fault due to

to Cracked Tree
Pole
Contact
Page 244 of 333

Measure
Plan for Flashed /Punctured or broken

insulators
Plan for Jumper Repairing
Plan for Tree Pruning / Trimming
Plan to reduce Faults due to Birds
Improper Earthing:
Page 245 of 333

Fault in Overhead Lines
Overhead lines are the main part of electrical power distribution system. These are used to carry the
electrical power from generating station / Sub-station to load centers/ consumer’s point. There are
several types of faults occurs at lines and there are several causes of fault occurrence at Over head
lines.
There are mainly two types of faults in the electrical power system. Those are symmetrical and
unsymmetrical faults.
1. Symmetrical faults
These are very severe faults and occur infrequently in the power systems. These are also called as
balanced faults and are of two types namely line to line to line to ground (L-L-L-G) and line to line
to line (L-L-L).
Only 2-5 percent of system faults are symmetrical faults. If these faults occur, system remains
balanced but results in severe damage to the electrical power system equipments.
Above figure shows two types of three phase symmetrical faults. Analysis of these fault is easy and
usually carried by per phase basis. Three phase fault analysis or information is required for
Page 246 of 333

selecting set-phase relays, rupturing capacity of the circuit breakers and rating of the protective
switchgear.
2. Unsymmetrical faults
These are very common and less severe than symmetrical faults. There are mainly three types
namely line to ground (L-G), line to line (L-L) and double line to ground (LL-G) faults.
Unsymmetrical faults
Line to ground fault (L-G) is most common fault and 65-70 percent of faults are of this type.
It causes the conductor to make contact with earth or ground. 15 to 20 percent of faults are double
line to ground and causes the two conductors to make contact with ground. Line to line faults occur
when two conductors make contact with each other mainly while swinging of lines due to winds
and 5- 10 percent of the faults are of this type.
These are also called unbalanced faults since their occurrence causes unbalance in the system.
Unbalance of the system means that that impedance values are different in each phase causing
unbalance current to flow in the phases. These are more difficult to analyze and are carried by per
phase basis similar to three phase balanced faults.
Causes of Overhead Line faults
1. Flashed /Punctured or broken insulators

 If flash over occurs, the insulator may be over heated which may ultimately results
into shuttering of it.
 If an insulator has any weak portion due to manufacturing defect, it may break from
that weak portion when mechanical stress is applied on it by its conductor.
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 If the surface of porcelain insulator is not properly glazed, moisture can stick over it.
This moisture along with deposited dust on the insulator surface, produces a
conducting path. As a result the flash over distance of the insulator is reduced. As
the flash over distance is reduced, the chance of failure of insulator due to flash over
becomes more.
Flashed/Broken Disc Insulator
Flashed/Broken Pin Insulator
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2. Damaged jumper/Conductor
The power conductor is connected to insulator on one side of the tower /pole and on the other side,
another power conductor is connected. But there is no electrical connection between these two
conductors. This electrical connection is served by a conducting wire which is termed as jumper. A
Damaged or jumper burnt is due to overloading, poor binding, manual intervention during
construction, under size cable /conductor jumper. These damaged /burnt jumpers leads to develop
conductor snapping and thus produce interruptions.
Burnt /damaged Jumpers
Page 249 of 333

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3. Fault due to Tree Contact
Many of the Transient faults at lines occurs due to tree falling or tree branch touching the line.
These kind of faults mostly occurs during spring & Rainy seasons, where growth of the Trees and
plants on the peak. Trees continuously grow, can fall over onto conductors, can drop branches onto
conductors, can push conductors together, and can serve as gateway for animals. When a tree
branch bridges two conductors, a fault does not occur immediately. This is because a moist tree
branch has a substantial resistance. A small current begins to flow and starts to dry out the wood
fibers. After several minutes, the cellulose will carbonize, resistance will be greatly reduced, and a
short circuit will occur. Branches brushing against a single phase conductor typically do not result
in system faults
.
Tree Branches in Vicinity of Line
Different Tree Zones near the Line
Page 253 of 333

4. Faults due to Birds
Birds are the most common cause of faults on both transmission / distribution systems and air
insulated substations. Different types of birds cause different types of problems, but they can
generally be classified as nesting birds, roosting birds, raptors, and woodpeckers.
Nesting birds commonly build their homes on Poles and in substations. Nesting materials can
cause faults, and bird excrement can contaminate insulators.
Nesting birds also attract predators such as raccoons, snakes, and cats. These predators can be a
worse reliability problem than the birds themselves
Birds/ Bird Nests at Line
Page 254 of 333

5. Fault due to Cracked Pole
In overhead lines, it has been many times that the supporting RCC/PCC pole has got cracks
in their bottom side. Although they can support the line temporary but as the time elapsed,
their cracks becomes so intense that some they they tilts the entire line which reduces the
phase to phase clearance and thus produce earth fault. It is also dangerous for general public
and animals resides in the area. So it is utmost important to look after such cracks in poles
and replace the same as soon as possible.
Improper muffing & Cracks in Pole
Page 255 of 333

6. Improper Earthing:
Earthing is a vital part of electrical system, ideally every 4th pole should be earthed properly
in order to provide low impedance path to the fault current appeared on the Overhead line.
In the absence of earthing, fault current / unbalance current will not get the appropriate path
to travel through ground.
In overhead lines,Failures / breaking of earth wires have been experienced due to:
 Cracking of dead-ends of the earth wires at cut points

 Breakage of earth wire strands
 Accumulation of moisture and water in suspension clamp earth wire grip
 Inefficient earthing
 Use of improper earth wires
 Not providing of mid-span joints at discontinuity of strand
Corrective & Preventive Action
1. Action Plan for Flashed /Punctured or broken insulators:

 Patrol the line carefully in order to check all the flashed / punctured insulators.
 Excessive deposit of pollutants on the insulators should be removed during
planned maintenance.
 Always use appropriate ratings of insulators.
 Avoid to install hair cracked insulators.
 Conductor should be firmly tightened at V-Groove of pin insulators.
 Pin of pin insulators should be properly screwed on the TOP HAMPER.
2. Plan for Jumper Repairing

 A fresh piece of cable/ Conductor should be taken for jumper making.
 Choose either the same rating of cable / conductor size or the next higher size of
conductor rating for making jumpers.
 Binding should be firm & tightened in LT conductors.
 PG Clamp, wedge connectors, D-clamp should be used at High voltage level.
 Thermal Scanning
Page 256 of 333

PG Connector
Wedge Connector
3. Plan for Tree Pruning / Trimming
Faults due to tree contact can be reduced by using tree pruner. It is a device which is used to trim
the unnecessary branches of the trees touching to the overhead lines. Tree trimming by Tree
trimming instrument saves time to climb on tree every time.
Page 257 of 333

Manual Tree Pruner Instrument
Tree Pruner Instrument
Page 258 of 333

Page 259 of 333

4. Plan to reduce Faults due to Birds
 Create awareness in the public to avoid sprinkle rice, eatables, flours balls near
the power lines. This can be done with the help of administration.
 Bird flapper should be used at lines where there are excessing amount of birds.
(Pics shown below).
 Bird nests should be removed immediately by taking emergency shutdown from
feeding Sub-station.
 Poly pro is an insulation sleeve with excellent dielectric strength, UV
stabilized used for covering fault prone sections of OH conductors (Pics
shown below).
Page 260 of 333

Bird Flapper
Bird Flapper
Page 261 of 333

Bird Guard
Bird Guard
Page 262 of 333

Poly Pro Insulating Sleeve
Poly Pro Insulating Sleeve
Page 263 of 333

5. Plan to Replace Cracked Pole :
Maintenance staff should replace the defected / damaged / cracked on priority. Proper pole
handling process must be follow during pole installation.
Following points should be kept in mind during erection of pole.
 Concrete poles shall be erected in such a way that the major axis is in line with
the direction of the power line.
 Jerking and swinging of poles caused by sudden lifting as well as striking of the
poles with ground or other objects shall be avoided
 Stringing of the conductors shall be done as soon as foundation concrete has
been cured and hardened and soil has been well compacted.
 Proper muffing shall be done.
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Right Method of Pole handling
Page 265 of 333

Wrong Method of Pole handling
6. Plan for Proper Earthing.

Every 4th pole should be properly and earth value should be less 5 Ohm. 7/10 SWG wire shall be
used for effective earthing. All the earthing ends shall be gripped with 70 sqmm Lugs with at
least 3nos of crimping.
Following kind of Earthing shall be done .However details of earthing procedure has been
mentioned in “ Role of earthing in Power distribution “ segment of Maintenance manual .
 Pipe electrode
 Rod electrode
 Plate electrode
Page 266 of 333

Aerial Bunched
Cable (ABC)
Page 267 of 333

Faulty Joints of Aerial Bunched Cables
Page 268 of 333

1) Metallic screens of single core ABC are floating at both ends.
2) At two locations hissing sound observed between metallic screen & messenger wire due to
pin hole on the outer sheath
3) As reported by zone, AB cable was burnt at three locations due to hissing sound
Symptoms prior to failure
At initial stage:
In Majority of cases, sparking &Hissing sound is developed between Copper screen & Messenger
wire of HT ABC.
Later stage:
Page 269 of 333

Outer Sheath burnt along the Messenger wire & damage of XLPE insulation due to heat of
sparking.
Cause of Sparking
The design of ABC is such that a substantial voltage induced at copper screen and is capable to
puncture the outer sheath along the messenger wire which is at earth potential resulted in sparking
& discharging sound.
Symptoms prior to failure :
At initial stage: In Majority of cases, sparking & hissing sound is developed between Copper
screen & Messenger wire of HT ABC because of improper connection between copper screen
& Messenger wire.
Later stage: Outer Sheath burnt along the Messenger wire & damage of XLPE insulation due
to heat of sparking.
Reason of Failure:
Design snags- a) Induction of high voltage at copper screen.

b) Under rated fault withstand capacity of Cu screen.
c) Manufacturing defects
Installation snags - Improper connection between Cu screen & Messenger.
Mechanical damage during installation.
Electrical stress
 Flash over due to Phase to phase & Phase to earth clearance at cable
termination
o Ensure sufficient clearance
 HT ABC /Termination failure due to improper connection between Earth braid

at End termination & Messenger wire.
o Ensure 1ɸ AL. conductor PVC insulated unarmoured cable with
thimble is used for connection between Earth Braids & Messenger wire.
o In existing design i.e with copper tape screen, 1Run X 25 sqmm cable
may be used at every termination.
 Termination failure due to Contaminated surface of terminations
o Ensure cleanliness of terminations
Thermal stress
Page 270 of 333

 Insulation degradation due to overloading
o Ensure recommended Loading
 Insulation degradation due to Hot spot at joints & Terminations
o Ensure proper Tightening/crimping of Lugs & Ferrules
 Insulation degradation due to Improper Earthing connections
o Ensure ABC & Messenger earthing connected to Earth/ Ground
o Earth connections should be properly tightened with all the metal part
and messenger wire. If any Joints have observed in the running portion
of GI wire, should be remove. Earthing should be done every 5 pole
apart & earth electrode should go upto water level.
o Earth Resistance value should be <1ohm.
Mechanical stress
 Stress develop due to Improper Bending Radius
o Ensure Proper Bending radius
 Stress/ Abrasion develop due to improper clearance between poles & AB cable
suspended on suspension clamps
o Ensure proper clearance between poles & ABC
 Stress develop due to Improper Span length
o Ensure proper span length
o Span Length should be depend on the size of the conductor/ABC cable
and pole height/type to maintain min. Sag & specified ground
clearance
o It would be 30-35 m for PCC pole
External damage
 Insulation Damaged during installation due to improper Laying practices.
o Ensure use of Rollers/ Pulleys during installations.
Water ingress
 Leakage current through the cable Insulation/cable failure, Corrosion in cable
conductor & Armor due ingress of water
o Ensure Lug seal to be intact at outdoor termination.
Design snags- a) Induction of high voltage at copper screen.

b) Under rated fault withstand capacity of Cu screen.
c) Manufacturing defects
Installation snags - Improper connection between Copper screen & Messenger
Page 271 of 333

Mechanical damage during installation.
Correctives Measures for Installation snags:

To connect copper screens to the messenger wire with at least 25 sqmm single core PVC
unarmored cable at both ends of the HT AB Cable section
DON’TS
1) Temporary joints must be restricted. In emergency case, while making temporary joint, copper
screen continuity must be maintained.
Standard joint must be installed at the earliest possible.
2 ) copper screens connected to messenger wire with fuse/ conductor strand wire.
Recommendation :
• HT ABC failure rate found high – route cause found to be inadequate SC rating of
HTABC available in India because of lack of Indian regulations about HT ABC.
• So we have adopted South African standards for HTABC in our specifications and
persuade Indian manufactures to comply for the same. So new HTABC with Al wire
screen for 10KA for one sec fault current rating has been introduced, old HT ABC was
with copper tape screen for 0.25KA for one sec fault current rating. So father
reduction in faults
Page 272 of 333

Best Practices for Jointing of AB Cables
Page 273 of 333

Page 274 of 333
Page 275 of 333
General Tools for Installation of AB Cable
Page 276 of 333

SN CHECK LIST DESCRIPTION ANNEXURE
CHECK LISTS/
ANNEXURES
Page 277 of 333

CHECK LIST FOR MAINTENANCE OF 33/11KV POWER
1 TRANSFORMER
2 CHECK LIST FOR MAINTENANCE OF ON-LOAD TAP CHANGER ANNEXURE-PTR/OLTC/MAIN/01
CHECK LIST FOR MAINTENANCE OF 33 & 11KV CIRCUIT
ANNEXURE-CB/MAIN/01
3 BREAKERS
4 CHECK LIST FOR MAINTENANCE OF CURRENT TRANSFORMERS ANNEXURE-CT/MAIN/-01
5 CHECK LIST FOR MAINTENANCE OF POTENTIAL TRANSFORMERS ANNEXURE-PT/MAIN/01
CHECK LIST FOR MAINTENANCE OF LIGHTNING (SURGE)
ANNEXURE-LA/MAIN/01
6 ARRESTERS
CHECK LIST FOR MAINTENANCE OF LINE ISOLATORS & EARTH
ANNEXURE-ISOL/MAIN/01
7 SWITCHES
CHECK LIST FOR MAINTENANCE OF BATTERY BANK & BATTERY
ANNEXURE-BAT/MAIN/01
8 CHARGERS
ANNEXURE-11KV VCB CONTROL
CHECK LIST FOR 11 KV VCB CONTROL PANEL
9 PANEL/MAIN/01
10 CHECK LIST FOR 33 KV OUT DOOR BUS ANNEXURE-33KV BUS/MAIN/01
11 CHECK LIST FOR 11 KV OUT DOOR BUS ANNEXURE-11 KV BUS/MAIN/01
ANNEXURE-11 KV APFC
CHECK LIST FOR APFC CONTROLLERS
12 /MAIN/01
13 CHECK LIST FOR AC DISTRIBUTION BOARD ANNEXURE-ACDB /MAIN/01
CHECK LIST FOR MAINTENANCE OF EARTHING SYSTEM AT GRID
14 SUBSTATION
ANNEXURE-33 KV LINES
15 /MAIN/01
16 CHECK LIST FOR MAINTENANCE OF 11 KV LINES
17 CHECK LIST FOR MAINTENANCE OF LT LINES
18 Annexure- AR-1 HT Auto-recloser
19 Annexures DT-1 Distribution Transformer
Annexures DT-2 Distribution Transformer
20
21
22
23
24
25
26
27 Annexure RMU-1 Ring Main Unit
28 Annexure RMU-2 Ring Main Unit
29 Annexure UG-1 Under Ground Cable
30 Annexure ABC-1 HT AB Cable
31 Annexure-ERT-1 HT Earthing
32 Annexure- G.O.-1 G.O. Switch
33 Annexure- OH-1 HT O/H Conductor
34 Annexure LT ACB LT ACB
35 Annexure- LT UG Cable LT UG Cable
Page 278 of 333

36 Annexure LT OH Conductor LT OH Conductor
37 Annexure LT ABC LT ABC
38 Annexure LT Earthing LT Earthing
39 Annexure LT Metering & Service Cable LT Metering & Service Cable
40 Annexure LT Feeder Pillar LT Feeder Pillar
41 Annexure LT Fuse Board LT Fuse Board
Page 279 of 333

CHECK LIST FOR MAINTENANCE OF 33/11KV POWER TRANSFORMER
Date &
Name of Grid:
Time
Season
Pre-requisite for Maintenance
Caution Order/PTW No.
T&P/material/PPEs
Safety Cotton Rag
ACTIO
PERMISSI
S. ITEM TO BE FREQUEN STATU N
BRIEF DESCRIPTION OF WORK BLE
NO. INSPECTED CY S TAKE
VALUES
N
Note down the temperature and record the
Ambient Temp Hourly NA
1 maximum daily ambient temperature.
Check that temp rise is reasonable. In case of
any abnormal variation, check the cooling
Winding/Oil Temp Hourly 100° C
system of T/F. If the same is not found in order.
2 Shut down the T/F for further investigation.
Check against rated figures. In case of any
Load/Voltage Hourly NA
3 variation, check the TPI.
Check against transformer oil level/ Daily each Above from
Oil level in transformer
1 temperature. Top up with dry oil, if necessary. shift Min level
Daily each Above from
Oil level in bushings Check for any oil leakage.
2 shift Min level
Check for cracked or broken. Replace if Daily each
Relief Vent diaphragm NA
3 necessary. shift
Check for any abnormal sound or excessive
For internal abnormal Daily each
chattering. Shut down the T/F in case of NA
noise. shift
4 abnormal noise, for further investigation.
Check for proper working, if provided. Replace, Daily each

Heaters in Junction Box NA
if found defective/damaged. shift
5
Check visually for tightness and sparking on NA
External connection Daily each
jumpers, bushings etc. on complete darkness.
(Leads/Jumpers) shift
6 Attend it, if required.
Check for any damage and signs of overheating NA
Bus bar and cable boxes Daily each
at their joints. Check for overheating of back
and cables shift
7 covers and attend, if found excessive heated.
1 Monthly
2 Monthly
Check for condition/colour of Silica gel. NA
3 Monthly
4 Recondition or replace as necessary. Monthly
5 Dehydrating breather Monthly

6 Ensure for free air passage Monthly NA
Tight, lid of the breather for air tightness to
Monthly NA
7 avoid entry
Check oil level in oil cup and make up oil, if
Monthly NA
8 required.
Page 280 of 333

Remove oil from dash pot and pour in fresh oil
Monthly NA
9 where required.
Examine for cracks, Paint and dirt deposits and
NA
Bushing and gaskets gap settings. clean or replace it. Check gaskets Monthly
10 for leakage.
Lubricate bearings, check gear box. Examine
Cooler fan and pump
Contacts, Check Manual control and interlocks. NA
bearings, motors and Monthly
Replace burnt or worn out contacts or other
operating mechanism
11 parts.
Lubricate bearings, Check gear box oil level and
On load tap changer NA
examine contacts. Clean/Replace burnt or worn Monthly
driving mechanism
12 out contacts
Check all circuits independently. Check step by
On load tap changer NA
step operation including limit switches. Attend Monthly
automatic control
13 if found faulty.
Check the I.R.values with 2.5KV rating meggar.
Convert it at 70 0 C and compare the values > 50 M-
Insulation resistance Monthly
with the value taken at the time of ohm
14 commissioning.
Examine relays and alarm contacts and their
Relays alarms,
operation, fuses etc. Check for relays
temperature alarm and Monthly NA
functioning clean or replace the contacts if
their circuits
15 required.
Set the rods for alignment and for proper gap NA
Arcing Horns Monthly
16 adjustment.
Measuring/Protection Check for sparking and tightness of connection NA
Monthly
17 CT’s and oil level.
NA
18 Remote/Manual Switch Check for proper functioning Monthly
Firefighting equipments Examine them and ensure that these are in order. Monthly NA
19
Note the oil level in the inspection glass of NA
Bucholtz’s relay Monthly
20 Bucholtz’s relay.
Check for dielectric strength. Dehydrate the oil,
Oil in T/F and tap
if necessary. Keep continuous record of test Quarterly NA
changer
1 results.
2 Ventilators Check that air passages are free. Quarterly NA
3 Bucholtz’s relay Check proper operation by lowering the oil Quarterly NA
4 Forced cooling system Megger testing of motors(pumps) Quarterly NA
Checking transformer ground connections for
Quarterly NA
5 tightness.
6 ThermoSyphen Filters Quarterly NA
7 Earth Resistance Check for tightness of earth connections. Quarterly NA
Measure earth resistance of the (a) T/F body,
neutral and other body parts, (b) Keep proper
Quarterly NA
record of test results. (Earth testing to be done
8 during driest part of the season)
Inspect all moving parts, contacts, brake shoes,
On load tap half yearly NA
1 motor etc. Clean, adjust or replace as required.
Check acidity, PPM & BDV & compare with
Oil in T/F half yearly NA
2 standard results.
Check Tan delta,,Sp.Resistively , sludge
Oil in T/F contents, DGA test, compare it with standard yearly NA
1 results.
Test oil for dielectric strength Dehydrate or
Oil filled bushing yearly NA
2 replace the oil, if necessary.
3 Cable box Check for sealing arrangements for filling holes. yearly NA
Page 281 of 333

Examine compound for cracks.
Examine for cracks and dirt deposits. Clean or
Surge diverter and gaps yearly NA
4 replace if necessary.
Check for tightness of bolts to avoid uneven
Gasket joints yearly NA
5 pressure. Replace damaged gasket.
Check oil pipes valves and plugs for tightness
Pipe connections yearly NA
6 and proper functioning.
7 Foundations Check for cracks, if any and setting. yearly NA
Test the bushings with a Hipet bushing tester
Bushings yearly NA
8 and compare with previous figures.
Pockets holding thermo-meter should be
Temperature indication yearly NA
9 checked. Oil to be replenished, if required.
Check pointer for free operation. . Adjust, if
Dial type oil gauge yearly NA
10 required.
11 Paint work Should be inspected yearly NA

Check for proper communication of the
conservator with T/F tank by draining some oil
yearly NA
through drain off valve and watching the oil in
12 gauge glass to drop.
Conservator tank In case, the oil does not drop, investigate and
remove the sludge or other obstructions after yearly NA
13 dis-assembling the tank.
Check for leakage of oil from glass side. Clean
yearly NA
14 the inspection glass.
Diverter switches for Yearly or
Check for worn out contacts. Filter oil
tap changer having non- after 5,000 NA
irrespective of all test. Replace worn out parts.
1 arcing selector switch operations
Internal inspection Clean the conservator
Oil conservator Two years NA
2 thoroughly
Mechanical inspection. Adjust floats, switches
Buchholtz relay Two years NA
3 etc. if required.
Non-arcing selection 3 years or
General inspection. Replace worn out parts and
switch of on load tap after 15,000 NA
filter the oil.
4 changer operations
Overall inspection including lifting of core and
7 to 10 years NA
5 coils
6 Major overhauls (complete) of transformers. 7 to 10 years NA
Once in 7
3000KVA and below (once in 7 yrs.) Above years
NA
3000KVA (once in 10 yrs.) once in 10
7 years
NA
NA
Note:Insulation resistance measurement, tan δ of winding/bushings, winding resistance at all taps to

be carried out once before expiry of warranty period and then to be continued as per schedule.
Visual observation of transformers and Reactors by going round, should be made daily to check for
any variations in noise, vibrations and any abnormality/leakages from cooler fans, oil pumps,
radiators, valves etc.
Page 282 of 333

WITNESSED BY:- JE/SDO SIGNATURE
Page 283 of 333

ANNEXURE-PTR/OLTC/MAIN/01
CHECK LIST FOR MAINTENANCE OF ON-LOAD TAP CHANGER

Name of Grid: Date & Time
Season
T&P/material/PPEs
Cotton Rag
ACTIO
Sr. ITEM TO BE FREQUENC Permissibl STATU
BRIEF DESCRIPTION OF WORK N
no. INSPECTED Y e Values S
TAKEN
Check leakage/seepage of oil from main tank to
1 DAILY N/A
OLTC tank
2 Oil leakage from OLTC. DAILY N/A
1 Silica gel breather MONTHLY N/A
2 Colour of silica gel crystals MONTHLY N/A
ON LOAD TAP
3 Oil in oil cup in silica gel breather MONTHLY N/A
CHANGER
4 Vermin proofing of OSR to avoid moisture ingress MONTHLY N/A
5 All unused wires are insulated MONTHLY N/A
QUARTERL
1 Prismatic oil gauge in OLTC conservator tank N/A
Y
QUARTERL
2 OSR oil glasses. N/A
Y
QUARTERL
3 Drain / filer valves N/A
Y
QUARTERL
4 Cracks / any abnormality in barrier board N/A
Y
QUARTERL
5 Local electrical operation of OLTC N/A
Y
QUARTERL
6 Step by Step operation of OLTC N/A
Y
QUARTERL
7 Electrical end limit (both upper and lower) N/A
Y
QUARTERL
8 Operation of OLTC N/A
Y
Space heater / thermostat/illumination lamp in QUARTERL
9 N/A
drive mechanism Y
HALF
1 OSR relay N/A
YEARLY
HALF >40KV at
2 ON LOAD TAP Oil BDV for OLTC tank
YEARLY 2.5 mm gap
CHANGER
HALF
3 Oil DGA
YEARLY
HALF
4 OSR trial operation Positive
YEARLY
HALF
5 OLTC operation manual/auto/local/remote Positive
YEARLY
1 Complete OLTC YEARLY N/A
2 OLTC drive mechanism cubicle YEARLY N/A
3 Diverter switch tank and barrier board YEARLY N/A
4 Fixed contacts in diverter switch YEARLY N/A
5 Moving contacts in diverter switch tank YEARLY N/A
6 Transition moving contact YEARLY N/A
Page 284 of 333

7 Tightness of internal connections YEARLY N/A
8 Braided flexible/collector ring/pre selector YEARLY N/A
9 Tap lead connection (for out tank OLTC only) YEARLY N/A
10 OSR connections YEARLY N/A
11 All gasketted joints YEARLY N/A
5 years or
after
As per pre
replacement
1 Transformer turn ratio / voltage ratio comm
of any
values
primary part
of OLTC
At the time of As per pre
1 Winding resistance of HV winding on all taps OLTC comm
maintenance values
WITNESSED BY:- JE/SDO SIGNATURE -
Page 285 of 333

ANNEXURE-
CB/MAIN/01
CHECK LIST FOR MAINTENANCE OF 33 & 11KV CIRCUIT BREAKERS
Date &
Name of Grid:
Time
Season
T&P/material/PPEs
Safety Cotton Rag
ACTIO
Permissi
Sr. ITEM TO BE FREQUEN STATU N
BRIEF DESCRIPTION OF WORK ble
no. INSPECTED CY S TAKE
Values
N
Examine that switchgear premises doors, circuit N/A
1 General cleanliness Daily
breaker etc. for general cleanliness.
N/A
2 Oil Check oil leakage, if so level be also ascertained. Daily
Check for temperature by touch and for any unusual N/A
3 Tank Daily
noise and smell.
Alarms and lamp indication Test the alarm circuit for continuity and lighting N/A
Daily
4 circuit etc. circuit and earthing system.
N/A
5 Safety aids Check safety aids for proper operation/condition. Daily
Check for load conditions on 3 phases, adjust relay N/A
Load Daily
6 setting. If necessary.
Indicating and measuring Check, indicating and measuring instruments for N/A
7 Daily
instruments correct reading and being in proper working order
N/A
1 Auxiliary fuses Check that auxiliary fuses are intact. Weekly
Check oil level in gauges of the tank/poles/oil filled N/A
2 Oil level and gauges Weekly
bushing. Replenish oil if found below normal.
Check for chipped or broken insulator, excessive N/A
Bushing or insulators Weekly
3 dirt film.
Visual inspection to see that equipment is in N/A
Closing solenoid of air
4 operating conditions Drain condensation from air Weekly
cylinder, motor or spring
cylinder.
Visual (or otherwise) inspection to see that N/A
Latch and trip mechanism Weekly
5 mechanism is in operating condition.
Visual inspection to see that solenoid trip device is N/A
6 Tripping solenoid Weekly
in operating condition.
Check cabinet heaters and see that they are in N/A
Cabinet lights and heaters service during cold weather. Replace burnt out Weekly
7 lamps.
N/A
8 Power supplies and wiring See that all power control circuit switches are closed Weekly
Check for external obstructions to breathers and N/A
Breathers and vents Weekly
9 vents and condition of silica gel.
Check whether nuts and bolts are tight and jumpers N/A
1 Nuts, bolts & Jumpers etc. Monthly
are properly connected.
N/A
2 Drain plug Check that drain plug is tight. Monthly
N/A
3 Operation counter Observe and record reading of operation counter. Monthly
Page 286 of 333

Check that breaker can be operated locally and in N/A
Local remote operation Quarterly
1 remote control operation.
N/A
2 Exhaust pipes Check and clean the exhaust pipes. Quarterly
Dash pot Check the working of dash pot. Quarterly N/A

3
Shutter mechanism and N/A
To check for proper working of shutter mechanism
4 trolley alignment for 11KV Quarterly
and to verify the alignment of trolley.
breakers
Check that manual operating lever or jack is kept on N/A
Manual operating device hand and is in visible condition. See that breaker is Quarterly
5 closable with it.
Observe mechanism during general tripping N/A
operations to see that everything is in working order.
Check pins, bearings and latch for wear, binding and
6 Latch and trip mechanism misalignment. Clean and lubricate the moving Quarterly
parts. Check latch carefully to see that it is not
becoming worn so as to unlatch from vibration or
stick or fail to trip. Tighten bolts and screws.
Observe operation during electrical tripping. See N/A
that full energy, snappy action of plunger is
Tripping solenoid Quarterly
obtained. Check plunger for sticking in guide Check
7 oil and insulation resistance.
Indicating and measuring Check for satisfactory operation, adjust where N/A
8 Quarterly
instruments necessary
Check IR value in ON and OFF positions between N/A
IR values contacts in off position. Check IR value of control Half yearly
1 cable with 500V megger.
N/A
2 Earth resistance Check earth resistance of body. Half yearly
N/A
This test may be conducted and also check that all
Slow closing test Half yearly
the three contacts are made simultaneously.
3
Adjustment of gap (for N/A
MOCB)& other type to The gap may be checked and adjusted to the
4 Half yearly
check the prescribed items required value.
by the manufacturer
Check and tighten wiring connection at terminal N/A
Wiring connections points. Inspect wiring for open circuit, short circuit Half yearly
5 and damaged insulation.
N/A
Check condition of contacts and refinish with fine
file if burnt or corroded. Check contact springs,
6 Aux.Switches operating rods and levers. Check closing and Half yearly
operating position with respect to main contacts
while breaker is slowly closed and opened manually.
To check for alignment of front door N/A
Control and protection
opening/closing for loose fitting, loose wiring of Half yearly
chamber of 11KV switch
7 opening in 11KV switchgear.
N/A
Insulated, jumpers CT and To check for tightness of connections, proper
8 Half yearly
PT in 11KV switchgear insulation and proper geometry.
Check for overheating and proper connection and N/A
11KV cable connections Half yearly
9 insulation.
Check foundation for cracks and settings. Settings of N/A
the breaker tank may break bushings or cause
1 Foundation Annual
misalignment of contacts or bindings of operating
mechanism.
Page 287 of 333

Check condition of paint. Inspect oil valves and N/A
Oil valves and plugs plugs. Flush out oil and clean the oil Annual
2 tank/quenching chambers.
Clean dirty gauge glasses and connections into tank. N/A
3 Oil levels and gauges Drain out and replace bushing oil if found dirty or Annual
discoloured.
N/A
Check to see that screens and baffles in vents or
Breathers and Vents Annual
breathers are not obstructed or broken.
4
Check air circuit breaker or other panels of N/A
insulating material for cracks and cleanliness. Check
5 Panels and cabinets Annual
condition of enclosing cabinets including hinges,
latches, locks door gaskets and paint.
Clean porcelain with water, chloroethene or other N/A
suitable cleaner. Repair chipped spots by painting
with lacquer such as red clay paint. Inspect gaskets
for leaks, tighten bolts. Check insulation resistance
Bushings or insulators with contacts closed and (Tan delta for condenser Annual
type). Check oil sample from bottom of bushing for
dielectric strength and moisture. Replace or
replenish oil if necessary. Check and clean interior
6 at least once every five years.
Tighten all nuts and ground connections. Refinish N/A
Main terminals and ground joint mating surface, if they have been overheated.
7 Annual
connections Inspect ground cable to see that it is not loose or
broken.
Remove the tanks or drain out oil, so that the N/A
contacts can be inspected, dress contacts, if rough
with a fine file. Check contacts voltage drop with
millivolt meter after inspecting reasonable current.
Main contacts Annual
Frequency of contact maintenance should be based
on numbers and severity of faults interrupted, rather
than a definite period. Check adjustment of gap
8 when required.
Check for loss of temperature damage or other N/A
9 Contact pressure spring Annual
deterioration.
Check flexible shunts of contact hinges for N/A
Flexible shunt Annual
10 overheating or damages. Tighten connections.
Check arc-rupturing blow out coils, magnetic circuit N/A
Magnetic, air or oil below
11 arc chutes, de ion grids, oil blasts or other Annual
out devices
interrupters for proper operations.
N/A
Check contact cross head for misalignment breaks
Cross heads Annual
bends or looseness on lift rods.
12
Check contacts for lift rods or brakes, weakening or N/A
13 Lift rods and guides wrapping and pulling out at ends. Checks adequacy Annual
of guides.
Check for loose locknuts, set screws, keys, bearing N/A
bent rods or twisted shafts etc. clean moving parts of
rust, dirt and accumulated grease and oil, wash out
Operating rods shafts and
bearings, pivots and gears with chloromethane or Annual
bell cranks
other suitable cleaner and operate breaker several
times to work out dirt and old lubricant. Lubricate
14 with new grease or oil.
Page 288 of 333

Observe mechanism during several operations to see N/A
that everything is in proper working order. Check
Closing solenoid air solenoid plunger for sticking in guides. Check coil
15 Annual
cylinder, meter or spring resistance and insulation resistance. Dismantle air
cylinder and clean and lubricate. Check spring for
proper tension and closing energy.
Check for condition of valve, and refit as necessary. N/A
Solenoid valves See that moving parts are free to operate. Check Annual
16 resistance and insulation resistance of solenoid coil.
Check that the operation counter is properly N/A
17 Operation counter Annual
registering the breaker operations.
Check that position indicator is properly registering N/A
Position indicator Annual
18 the breaker operations.
N/A
Check for proper setting and adjust as necessary.
19 Dashpots Annual
Clean out and replenish liquid in liquid dashpot.
N/A
Check condition of metal and hardware. Repaint as
Mechanism cabinets necessary. See that door gaskets are tight and Annual
properly dust and vermin proof.
20
N/A
Inspect fuses of circuit breakers in all power and
21 Power supply and wiring control supply circuits, check in insulation Annual
resistance of wiring with devices connected.
N/A
Check dielectric strength of the insulating oil in the
main tanks and oil filled bushings. Oil should be
Oil dielectric test and filtered or replaced if dielectric strength is found to
acidity test dependent on below 25 KV, or if there is a noticeable amount of Annual
actual tripping carbon in suspension on the bottom of the tanks.
Also check ratio and phase angle adjustments, the
acidity of the oil.
22
Some breakers particularly those carrying high N/A
values of current have a tendency to develop contact
heating if left closed for long periods. Operating and
closing the breakers several times at intervals, as
23 Operation Annual
system operation permit, may alleviate the heating
by wiping the oxide from the contact surfaces, as
well as demonstrate that the breaker is in operating
condition.
Check tap setting and adjustments at terminal board N/A

to see that they agree with diagrams. Check
Bushing current insulations resistance of wiring with devices
transformers and potential connected. Check of potential devices if changes Annual
devices have been made in secondary connection and
burden. Tighten connections, including potential
24 devices top into bushing.
Testing of oil in oil filled Once in two N/A
1
bushings years
N/A
Cleaning blast tube
Once in two
internally and checking
years
clamping down nuts.
2
Page 289 of 333

Overhaul and checking N/A
efficiency of main
compressor. Complete
overhaul of the O.C.B.
Once in two
3 (The period can be changed
years
depending upon the lead
cycle of the equipment and
manufactures
recommendations).
ANNEXURE-CT/MAIN/-01
Page 290 of 333

CHECK LIST FOR MAINTENANCE OF CURRENT TRANSFORMERS

Season
T&P/material/PPEs
Earth resistance Tester
Cotton Rag
Sr. BRIEF DESCRIPTION OF FREQUENC Permissible STATU ACTION
ITEM TO BE INSPECTED
no. WORK Y Values S TAKEN
Visual Damages & Deterioration
1 WEEKLY N/A
if any
2 Oil Leakage if any WEEKLY N/A
3 Oil Level in CT WEEKLY N/A
6 Check condition of the Structure WEEKLY N/A
All unused wire are insulated in
7 WEEKLY N/A
CT
All cables entry into CT is through
8 WEEKLY N/A
cable gland
Check any abnormal sound with
9 WEEKLY N/A
Ultra probe 15000
1 CT Bushing MONTHLY N/A
2 CURRENT TRANSFORMER Secondary Terminals MONTHLY N/A
3 CT Junction Box MONTHLY N/A
4 Oil Inspection Window MONTHLY N/A
6 Primary Connections MONTHLY N/A
7 Secondary Connections MONTHLY N/A
8 Mounting Frames MONTHLY N/A
9 Earthing CT/Frame/JB MONTHLY N/A
10 JB Connections MONTHLY N/A
Vermin Proofing of CT Junction
11 MONTHLY N/A
Box/Sec Terminal
HALF
1 IR value of Primary to Earth >200M Ohm
YEARLY
HALF
2 IR value of Secondary to Earth >200 M Ohm
YEARLY
HALF
3 IR Value of Primary to Secondary >200M Ohm
YEARLY
HALF
4 Tan Delta <5%
YEARLY
As per CT
1 CT Analysis YEARLY
Type
Page 291 of 333

ANNEXURE-PT/MAIN/01
CHECK LIST FOR MAINTENANCE OF POTENTIAL
TRANSFORMERS
Season
T&P/material/PPEs
Safety Cotton Rag
ACTIO
Sr. ITEM TO BE Permissible STAT N
BRIEF DESCRIPTION OF WORK FREQUENCY
no. INSPECTED Values US TAKE
N
Check any abnormal sound with
DAILY N/A
1 ultrasonic detector
2 Visual damages and deterioration if any DAILY N/A
1 Oil Level sight Glass Weekly N/A
2 Earthing PT/Frame/JB Weekly N/A
3 JB Connections Weekly N/A
4 Oil Leakage if any Weekly N/A
POTENTIAL Check condition of fuses & that all fuses
5 TRANSFORMERS Weekly N/A
are intact
1 PT Bushing Quartarly N/A
2 PT Junction Box Quartarly N/A
3 Secondary Connections Quartarly N/A
4 IR value of Primary to Earth Quartarly >200M Ohm
5 IR value of Secondary to Earth Quartarly >200 M Ohm
6 Oil Level in PT Quartarly N/A
Vermin Proofing of PT Junction Box/Sec
7 Quartarly N/A
Terminal
1 Secondary Terminals Annually N/A
2 Primary Connections Annually N/A
3 Mounting Frames Annually N/A
4 IR Value of Primary to Secondary Annually >200 M Ohm
Correct Rating of PT Fuse, up to C&R
5 Annually N/A
Panel
6 Check condition of the Structure Annually N/A
7 Check all unused wires are insulated Annually N/A
As per pre
1 PT Analysis Once in 3 Yrs.
common values
Page 292 of 333

ANNEXURE-LA/MAIN/01
CHECK LIST FOR MAINTENANCE OF LIGHTNING (SURGE)

ARRESTERS
Date &
Name of Grid:
Time
Season
T&P/material/PPEs
Cotton Rag
ACTIO
Sr. ITEM TO BE FREQUE Permissibl STATU N
BRIEF DESCRIPTION OF WORK
no. INSPECTED NCY e Values S TAKE
N
Note and record operation indicator reading along N/A
1 Surge Counter DAILY
with leakage current.
Usual inspection to detect cracking setting or shifting MONTHL N/A
2 Base & support
of base of supports. Y
Check that surge monitor is properly connected and is MONTHL N/A
3 Surge Monitor
in working order and shows a leakage current. Y
Jumpers and HALF N/A
1
clamps Check jumpers and clamps for tightness. YEARLY
Porcelain Clean porcelain insulators and arrestor unit shells. N/A
HALF
2 shells and Repair chipped spots on porcelain with lacquer such
YEARLY
insulators as red clay paint.
Check and tighten grading rings on high voltage HALF N/A
3 Grading rings
arrestors. YEARLY
Check external gaps. Smooth off burnt spots and HALF N/A
4 Gaps
readjust spacing. YEARLY
See that weather sheds and hooks of oxide film N/A
Weather sheds
1 arrestors are securely fastened in place, repaint if ANNUAL
and hooks
necessary.
Check and tighten line and ground connections. N/A
Line and Ground Check ground lead for corrosion or damage below
2 ANNUAL
connection ground line. Check ground resistance. See that all leads
are as short and direct as possible.
Operation tests N/A
(Surge
generating To check the general working of lightening
3 ANNUAL
equipment arrestors by M&P Divisions.
under
procurement)
Page 293 of 333

ANNEXURE-ISOL/MAIN/01
CHECK LIST FOR MAINTENANCE OF LINE ISOLATORS & EARTH

SWITCHES
Date &
Name of Grid:
Time
Season
T&P/material/PPEs
Cotton Rag
Permissi
ITEM TO BE FREQUEN STAT ACTION
Sr. no. BRIEF DESCRIPTION OF WORK ble
INSPECTED CY US TAKEN
Values
N/A
Check for cracked or broken porcelain and
excessive dirt film and to undertake repair of
1 Insulators WEEKLY
chipped spots by painting with lacquer such as red
clay paint.
N/A
Blades and Check that blades are properly seated in the WEEKLY
2 contacts contacts..
Blades and N/A
3 latches and Check that blade latches where provided are WEEKLY
stops engaged.
Check that switches are properly locked in the open N/A
Locks and inter or closed position as required by padlocks or other WEEKLY
4 locks key type locks or interlocks.
Bolts, Nuts & Check bolts, nuts and jumpers for tightness. Apply N/A
1 Quarterly
Jumpers petroleum jelly on male and female contacts.
I.R,value and N/A
HALF
earth Check IR, value with 2.5KV megger and earth
YEARLY
1 resistance resistance. Check that double earthing is provided.
N/A
Check condition of contacts and refinish with fine
Auxiliary & file if burnt or corroded. Check contact spring HALF
2 operating rod and lever. Check closing and opening
limit switches YEARLY
position with respect to main switch contacts or
travel or motor mechanism.
N/A
To check for proper engagement of emergency HALF
Manual operating handle and further its operation is smooth YEARLY
3 operating Rod and satisfactory.
ANNUALL N/A
4
Line & ground Y
Blades and N/A
contacts ANNUALL
Y
5
Page 294 of 333

ANNEXURE-BAT/MAIN/01
CHECK LIST FOR MAINTENANCE OF BATTERY BANK & BATTERY

CHARGERS
Name of Date &
Grid: Time
Season
Caution
Order/P
TW No.
T&P/mat
erial/PP
Es
Cotton
Rag
ACTIO
ITEM TO BE FREQUEN Permissibl STATU N
Sr. no. BRIEF DESCRIPTION OF WORK
INSPECTED CY e Values S TAKE
N
See that battery room entrance doors are kept N/A
Battery room closed and that ventilation to outside air are open
1 DAILY
and ventilation and air is circulated by running of the exhaust
fan
Check charging rate hourly. Check and record N/A
pilot cell specific gravity, temperature and
DAILY
floating
2 Operation voltage
Bulb for dry N/A
3 rectifier Check for burnt bulb and replace when DAILY
element necessary.
Checking specific gravity and voltage of each N/A
cell of lead acid cells. (before and after DAILY
4 Operations charging) (weekly when trickle charge exists)
DAILY N/A
5 Perform leakage test by lamp or (EACH
Leakage test voltmeter method. SHIFT)
Cleaning of terminals, applying Vaseline and N/A
topping up with distilled water. (for lead acid WEEKLY
1 batteries)
N/A
Cell Jars and Check for cracked or leaking jars or covers and
1 replace when necessary. Keep jars and covers MONTHLY
covers
clean.
Inspect plates(in case of transparent containers N/A
only) carefully for signs of deterioration due to
MONTHLY
improper charging. Note quantity, colour
2 Plates and texture of sediment.
See that the separators remain in place and are N/A
3 keeping the plates properly spaced(in case of MONTHLY
Separators transparent containers only)
N/A
Check electrolyte level and add distilled MONTHLY
4 Electrolyte water when required.
Acid and See that enough distilled water and acid are kept N/A
5 distilled water in storage to meet current needs. Check MONTHLY
storage containers for cleanliness.
Page 295 of 333

Check and record specific gravity and voltage of N/A
MONTHLY
6 Operation each cell.
Check general condition and operating N/A
7 Transformer or temperature of transformer or reactor used in MONTHLY
reactor bulb or dry type rectifiers.
Checking all connections of charger and battery N/A
Quarterly
1 Connections for tightness.
Discharging This is required to be carried out as prescribed by N/A
1 and charging the manufacturer in order to prolong the life of Half yearly
cycle the battery.
Bulb or dry See the copper oxide or selenium rectifier N/A
rectifier elements are not operating too hot, this will Half yearly
2 element shorten their life.
Check that sliding mechanism of the rheostat is N/A
3 Rheostat in order and clean the sliding contacts, if Half yearly
required. Check contact heating and spring
pressure.
Check metallic structures/parts located in the N/A
room for corrosion and clean and paint
as necessary, check ventilation system fan etc.
for proper operation to make sure that no Annual
explosive gases are being accumulated in the
Battery room battery room due to excessive gassing or poor
1 and ventilation ventilation.
Inspect concretes base or wooden racks for N/A
2 deterioration. Repair and repaint with acid Annual
Base or rack resistant paint as necessary.
N/A
Check base pad of sheet rubber, or other material Annual
3 Case pad for deterioration from acid or other causes.
Clean acid corrosion from connectors and N/A
4 Inter cell terminals should be lead coated. Tighten Annual
connectors terminals and apply petroleum jelly for exposed
and terminals surface.
Hydrometer and Check condition of hydrometer and N/A
thermo thermometers used for daily and monthly Annual
5 meter readings against spare units held in reserve.
See that the sink, funnels, fillers and other N/A
6 Sink funnel distilled water and acid handling facilities kept Annual
and filters clean and in good useable conditions.
Check still for proper operation, adequacy N/A
and purity of distilled water delivered. See Annual
7 Water still that equipment is kept clean
Complete overhauling of the battery. (as N/A
8 Annual
recommended by manufacturer)
N/A
N/A
N/A
N/A
N/A
Page 296 of 333

CHECK LIST FOR CONTROL PANEL
Season
Caution
Order/PTW No.
T&P/material/PP
Es
Cotton Rag
Maintenance Activities
Permissib Action
S.NO. BRIEF DESCRIPTION OF WORK Frequency Status
le Values Taken
1 Check all indication lamps for working DAILY N/A
2 Check illumination lamp / power socket for working DAILY N/A
1 Vermin proofing of panel and door interlock switch MONTHLY N/A
2 Check & ensure that L/R switch is at remote position. MONTHLY N/A
3 Check fuse / MCB rating MONTHLY N/A
4 Check rating of fuses/MCB MONTHLY N/A
HALF
1 Control Panel Interior. N/A
YEARLY
HALF
2 Control Panel external surface. N/A
YEARLY
HALF
3 Relay / Contactors with air blower (from distance) N/A
YEARLY
HALF
4 All Control Connections. N/A
YEARLY
HALF
5 Earthing Connection wherever provided N/A
YEARLY
HALF
6 Inter panel Coupling. N/A
YEARLY
HALF
7 Multicore Cable Glands. N/A
YEARLY
HALF
8 Check cubicle heater / thermostat for correct operation N/A
YEARLY
HALF
9 Dressing of wiring. N/A
YEARLY
HALF
10 Check door bidding for dust proofing. N/A
YEARLY
Check & ensure that all multicore cables are earthed at HALF
11 N/A
switchyard side only. YEARLY
Check and ensure that relay healthy indication is HALF
12 N/A
glowing. YEARLY
HALF
13 Check that all unused wires are insulated. N/A
YEARLY
At the time of
1 All Protection Connections. N/A
Prot checking
At the time of
1 All Communication Connections. N/A
Com checking
At the time of >50 M
1 Insulation resistance of Multicore cables
commissioning Ohm
Page 297 of 333

CHECK LIST FOR MAINTENANCE OF EARTHING SYSTEM AT GRID

SUBSTATION
Name of
Date & Time
Grid:
Season
Caution
Order/PTW
No.
T&P/materia
l/PPEs
Maintenance Activities
Permissible Stat Action
S.NO. BRIEF DESCRIPTION OF WORK Frequency
Values us Taken
1 All Earth pits MONTHLY N/A
HALF
1 All Earth connections at Earth pits. N/A
YEARLY
HALF
2 Check all equipments for double earthing N/A
YEARLY
HALF
3 Check all earthing conductors for adequacy & proper tightness. N/A
YEARLY
HALF
4 Check proper clamping of earthing pipe and earthing conductor. N/A
YEARLY
HALF
5 Check numbering of all earth pits. N/A
YEARLY
HALF
6 Check availability of Cast Iron lid for each earthing pit. N/A
YEARLY
Check exposed portion of earth conductor for Galvanizing or HALF
7 N/A
painting YEARLY
Check & ensure painting of Earth isolator box with Green HALF
8 N/A
colour for fast identification YEARLY
Check that each multicore cable is grounded through cable HALF
9 N/A
gland. YEARLY
Check and ensure that all power cables are earthed at one end HALF
10 N/A
only YEARLY
Check and ensure all multicore cables are earthed at switchyard HALF
11 N/A
end only or alternatively at one end only. YEARLY
Check and ensure that Substation building earth is connected to

HALF
12 separate earth pit / pits and then the same is extended to mesh N/A
YEARLY
earthing in switchyard.
Check and ensure that individual Transformer neutral is

HALF
13 connected to separate earth pit and then the same is extended to N/A
YEARLY
mesh earthing in switchyard.
HALF
14 All Earth connections at equipment mounting frames N/A
YEARLY
Page 298 of 333

All Earth pits resistance for Power / Distribution Transformer
15 YEARLY < 5 Ohm
neutral
16 All Earth pits resistance for LAs YEARLY < 5 Ohm
17 Resistance of earth mesh YEARLY < 1 Ohm
18 Final Status and Remarks
Page 299 of 333

ANNEXURE-33 KV LINES /MAIN/01

ITEM TO ACTI
Permissi
Sr. BE FREQUEN STAT ON
no. INSPECT CY US TAKE
Values
ED N
Damages/broken poles or for ground level erosion and
1 corrosions where the pole is not capable of safely Quarterly NA
supporting its load.
Bowed or leaning poles due to improper guying or
2 Quarterly NA
overloading.
Poles- Unauthorized attachments such as fencing, aerial wires
3 Quarterly NA
Steel etc.
Wood Poles which are very much exposed to hitting/striking
4 Quarterly NA
Cement of animals and bumping and scrapping by vehicles
5 If the pole Number plate is still distinct Quarterly NA
Check the condition of foundation and attend it, if
6 Quarterly NA
necessary.
Examine if pole requires painting of in case of
7 Quarterly NA
steel/wood poles
1 Correct direction and proper angle of the stay Quarterly NA
2 Loose broken or any other damage done to stays Quarterly NA
Stays Whether stay insulator is intact/whether stay is properly
3 Quarterly NA
earthed
4 If stay rods are corroded. Attend the same if required. Quarterly NA
1 If the cross-arms/clamps/knee has/have slipped. Quarterly NA
2 Cross Bending of cross arms due to uneven tension Quarterly NA
arms and
3 pole top Excessive rusting of the cross arms bracings etc. Quarterly NA
4 steel Cracked or splitting or the wooden cross-arms Quarterly NA
works Loose or damaged bracings. Attend the same, if
5 Quarterly NA
required.
1 Broken or chipped porcelain flashover marks Quarterly NA
2 Tilted insulators Quarterly NA
Insulators Excessive deposit of dust/salt/coal and other pollution
3 Quarterly NA
clean the same.
Excessive rusting of fittings, replace the same, if
4 Quarterly NA
required.
Examine, if securely tied to the insulator/pole/cross-
1 Quarterly NA
arms
2 Proper sag, set right the same, if required. Quarterly NA
Conductor Proximity of trees and other objects including building
3 s and earth Quarterly NA
etc.
wire
Sufficient clearance between conductors and earth wire
4 Quarterly NA
and also from the ground
Sufficient clearance from other electric/telephone lines
5 Quarterly NA
passing along below or above it.
Page 300 of 333

ITEM TO ACTI
Permissi
Values
ED N
6 Earth wire is properly supported Quarterly NA
All the line guards are intact and installed where
7 Quarterly NA
necessary
8 If joints in the jumpers and conductors appear all right Quarterly NA
9 Broken conductors strands Quarterly NA
10 Nicking near insulator neck/or near conductor clamps Quarterly NA
11 Conductor Bindings wire has not become lose and open Quarterly NA
12 s and earth Mid span joints have not cracked. Quarterly NA
wire All joints and jumpers of aluminum conductors have
13 proper clamps/jointing sleeves. Straight the same, if Quarterly NA
required.
Proper supporting and jointing two ends of the jumpers
1 Quarterly NA
with suitable clamps.
2 Sufficient clearance between jumpers on the 3-phases Quarterly NA
Jumpers
3 and other Sufficient clearance of jumpers from metal Quarterly NA
4 line Provision of proper insulation of jumpers Quarterly NA
accessorie
Signs of over-heating and burnings on jumpers and
5 s Quarterly NA
other fittings.
Loose/defective clamps jointing sleeves, bolts and nuts,
6 Quarterly NA
and other fittings.
Cut off the trees branches where necessary to maintain
1
a minimum clearance of 1.8m on each side of the line Half yearly NA
2 Tree Remove all dead wood. Half yearly NA
trimming
and bird's Remove all bird's nests. (once before the monsoons or
3
nests etc. earlier, if necessary) Half yearly NA
1 Tighten the loose stays. Annually NA
2 Replace the broken/damaged stays and stay bows Annually NA
3 Stays Replace the broken stay insulator/recondition the Earth Annually NA
Provide sufficient barbed wire/cattle guards on the stay
4
to avoid rubbing of cattles Annually NA
Replace the broken/splitted/cracked/bent cross arms
1
by new ones. Annually NA
Cross Bring in position the slipped cross
2
arms arms/clamps/bracings. Annually NA
Paint the steel cross arms and bracings etc. If
3
excessively rusted. Annually NA
Insulators Clean and check for cracked/chipped and
1
and punctured insulators. Replace, where necessary. Annually NA
Page 301 of 333

ITEM TO ACTI
Permissi
Values
ED N
fittings Examine for the surface contamination and
remove it by wiping with a soft cloth (do not use cotton
waste). If the deposit has set hard, a weak acidic
2
solution may be used.
The insulators be checked twice a year preferably or
before and after (monsoons) Annually NA
1 Tighten loose bindings and replace damaged ones.
Annually NA
Examine for corrosion at the joints of
2 conductors and insulators. Clean and renew, where
necessary. Annually NA
3 Examine closely for broken strands

Conductor particularly at the clamps and insulators due to
s and vibration and repair, where necessary. Annually NA
earth Examine general condition of the conductor
4 wires and earth wires i.e. for kinks, crushed spots over/under
tensioning, etc., and recondition, where necessary. Annually NA
Examine for any loose/cracked joints of
5 conductors in the mid span and recondition where
necessary. Annually NA
Examine for any loose/cracked joints slipping
6 of conductors from the clamps. Tighten all clamps and
fittings. Annually NA
Clean and examine insulators for cracks or
1
flashover. Replace, where necessary. Annually NA
Perform impulse voltage spark over test and
leakage current test to know the condition of
2 Lightening the arrester; replace in case of unsatisfactory
arrestor results. Annually NA
3 Keep records of test results. Annually NA
Check and tighten all line connections and
4
earth leads Annually NA
Replace all broken earth leads and tighten others.
Earthing Measure earth resistance of various earths with
1
System earth. Tester. In case of low values, recondition
them. Annually NA
Anti-
climbing
devices
2 and
danger Recondition the anti-climbing devices such as barbed
plates wire, locks, etc., paint and reprint the danger plated if
etc. defaced. Annually NA
Page 302 of 333

ITEM TO
Permiss
Sr. BE FREQUE STAT
BRIEF DESCRIPTION OF WORK ible ACTION TAKEN
no. INSPECTE NCY US
Values
D
Poles
Steel
Wood
Cement
Stays Quarterly
Cross arms /
Same as recommended for the items as 33
1 Conductor Half
KV lines in addition to the followings
Insulator year/
Earthwire Year
Lightning
arrestor
Earthing
System
1 Check for the following: A method for field
testing for switch
2 For smooth operation Quarterly contacts with live line
consists in using an
Evidence of over-heating burning, Quarterly insulated rod (for 11
3
corrosion/pitting on the switch contacts. KV) adjustable height
4 Broken or damaged insulators. Quarterly having at its upper end
a tallow candle fixed in
5 Proper and tight earth connections. Quarterly a clip Hold the candle
G.O. against the hot contact
Fuse links for continuity, tightness of Quarterly
6 Switchs for a few seconds &
(with fuse connections and correct rating. then examine. If the
7 unit) Proper locking arrangement. Quarterly grease slightly melts,
mark the contact for
8 Proper alignment of switch contracts. Quarterly attention. If the grease
runs, the switch
Proper and complete fitting of male contacts Quarterly requires early attention
9
into the female ones. and if it smokes,
Quarterly dangerous condition is
Arcing horns are intact. assumed, the switch
10
required immediate
attention.
1 Check for the following:
Proper supporting of the cable and the cable
2 Quarterly
boxes.
3 11 KV Damaged insulators. Quarterly
Cable and Oil and compound leaks and that the cable
4 Cable Quarterly
box is properly tippe up with the compound.
5 boxes. Tight and intact connections. Quarterly
6 Proper earthing. Quarterly
7 Overall condition of the cable and joint. Quarterly
G.O. Half- These points should be
Cleanliness: Clean all dust and other
1 Switch yearly particularly checked
deposits with neat and dry cloth.
(with fuse (its when contacts are
Page 303 of 333

ITEM TO
Permiss
Sr. BE FREQUE STAT
no. INSPECTE NCY US
Values
D
unit) maintena replaced.
nce may Fixed and moving
Switch contacts: (1) Check for the aliment, be done contacts may be
adequate pressure and smooth operation and even dressed by using fine
2 adjust, where necessary. (2) Examine for earlier as file/fine sand paper.
burning/over-heating or other damages. the Use of rough sand
Recondition or replace, where necessary. functioni paper be avoided.
ng of GO
Petroleum jelly/ white
Switches
Vaseline or other
Insulators: (1) Check for cracks, chipping is
suitable contact
and other defects, replace, where necessary. generally
lubricant should
3 (2) Remove dirt, coal and other pollutions in
applied on contacts
by wiping with soft cloth. Use weak acidic disorder
grease should be
solution, if the deposit has set hard. and is
applied on all the
always a
moving parts.
source of
Arcing Herms : Check if those are intact trouble).
4
and replace, if damaged/burnt.
Mechanism: Clean, examine and renew
5 worn out parts. Re-lubricate and check for
correct operation.
Fuse unit: Replace old fuses with new ones
6
of right type and capacity and proper length.
Main connections and Earthing: proceed as
7 described under separate heading of
‘Jumpers’ and ‘Earthing devices’.
General : check all hardware and tighten, if
8
needed.
1 Clean and examine for damaged bushings Annually
11 KV Check for compound level, if there is Annually
2
Cable and leakage.
cable Perform insulation resistance test, Annually
3
boxes recondition or replace, where necessary.
Keep continuous records of insulation Annually
4
resistance.
Page 304 of 333

CHECK LIST FOR MAINTENANCE OF LT LINES
ITEM TO
Permiss
Sr. BE FREQUENC STA
no. INSPECT Y TUS
Values
ED
Pole
Stay
Cross
arm
Same as recommended for these items under schedule This becomes
Conductor Four
1 for HT Lines (Whether cobwebs, kite strings, etc., source of heavy
Insulator Monthly
hanging on the conductor) leakage when wet.
Connectors
Cable
Boxes
etc.
1 Check for the flowing:
2 If the switch with cover is intact. Monthly
3 If the cable/switch running hot. Monthly
4 LT Broken cut-outs. Monthly
5 Switch Signs of over-heating/burning on contacts. Monthly
6 Proper size of fuse wire. Monthly
7 If the switch is properly earthed. Monthly
8 Safety from rain water etc. Monthly
Check lead on the LT circuit and replace the LT
1 cable/LT switch by higher capacity one, where Half-Yearly
necessary.
Replace the damaged LT Cable with new one of right
2 Half-Yearly
capacity.
3 Examine the switch for smooth operation. Half-Yearly
4 Replace the burnt/cracked cut-outs. Half-Yearly
5 LT Recondition the switch contacts Half-Yearly
Switch
6 Replace the old fuses with new ones of right capacity. Half-Yearly
7 Tighten all connections. Half-Yearly
Ensure that the inlet of the cable into the switch is
8 plugged with plastic compound to avoid entry of rain Half-Yearly
water. Refill, where necessary.
Clean off the cob-web and other nests etc., from the
9 Half-Yearly
inside of the switch.
Poles
Stays
One to two
Cross
yearly
arm
Same as recommended for these items under schedule (depending
1 Conductor
for HT Lines. upon the
Insulator
volume of
Connectors
work)
Cable
boxes etc.
Annexure- AR-1
Page 305 of 333

(To be filled by JUNIOR ENGINEER/Project Engineer)
1 Operational checks Status

i Switchgear ON/OFF through PTCC OK Not OK
ii Switchgear ON/OFF manual (in 'Sectionaliser/ RL series' only) OK Not OK
iii Mechanical Interlocks OK Not OK
Switchgear tripping through Emergency Lever (in U Series
iv only) OK Not OK
v Position Indicator (Mechanical) OK Not OK
2 Electrical Test
a Local / Remote - ON / OFF OK Not OK
b LED indication on PTCC Breaker Close OK Not OK
c LED indication on PTCC Breaker Open OK Not OK
Electrical interlock - Enable / Disable switch OK Not OK OK
d Not OK OK Not OK
e Battery voltage ( Aux supply should be turn off ) ( 24VDC ) OK Not OK
f Auxiliary supply Normal Abnormal
g Check/ Download WSOS history logs Yes No
h Current values on PTCC ( After switch ON ) OK Not OK
Voltage values on PTCC ( After switch ON ) OK Not OK OK
i Not OK OK Not OK
j Pressure reading of SF6 on PTCC ( RL Type only ) OK Not OK
k Check PT fuse intactness and continuity OK Not OK
l ON / OFF operation through Battery OK Not OK
a Visual inspection for missing parts OK Not OK
b Cleaning of PTCC panel, ACR ( dust etc ) OK Not OK
c Connection Check of Plugs and CAPM compartment OK Not OK
d Cable entry point sealed in PTCC OK Not OK
Page 306 of 333

E Stress on bushing due to cable/conductor connection OK Not OK
f Method of Conductor connection on bushing OK Not OK
g Tie / clamp support to umbilical cable (control cable) OK Not OK
h Terminal Connectors OK Not OK
i Visual inspection of any damages OK Not OK
j Presence of Earthing OK Not OK
k Earthing ( Pit ) Resistance test results OK Not OK
l Tightening of Cable clamps / connectors to bushing OK Not OK
m Condition of Male/Female Pins on plugs (PTCC / S/G) OK Not OK
n Clearance of PT with Guard wire OK Not OK
o Presence of PT bushing insulated Caps OK Not OK
6 Condition of Electronic Module - OK Not OK
a. CAPM / SCEM / CCEM / OCPM OK Not OK
b. MDIM3 / MDIM2 OK Not OK
7 Status of battery cells terminals, links OK Not OK
8 Modem Functionality OK Not OK
Remarks:
Witnessed by:
Junior Engineer: S.D.O
Page 307 of 333

Annexures DT-1
Check List for oil filled Distribution Transformers: Checked
(To be filled by Junior Engineer)
1) Check that the colour of the silica gel in the breather is blue.
2) Check the breather for any cracks, holes, transparency and oil in the oil cup.
3) Check for any signs of No arcing/pitting mark on Bus-bar & palm connector.
4) Ensure that there is no leakage of oil from gaskets, flanges, valves, radiators,
bushings etc. Ensure oil level of conservator & cleaning of glass of conservator.
5) Check that the bushing surface is clean.
6) Check the bushings for any crack or any chipping of porcelain.
7) Check the earthing of the tank cover to tank.
8) Check the condition of neutral & transformer body grounding
9) Ensure that the surface of radiator is clean.
10) Check the earthing of fencing (enclosure) with two separate earths.
Witnessed by:
Junior Engineer: SDO:
Page 308 of 333

Annexures DT-2
Test Results:
Test Limits Date of Actual value Remarks

Parameters Test
IR test. 1. IR value shall be

equal for all three
phases for HT-E,
LT-E, HT-LT.
2. Normally IR value
shall be minimum
100 MΩ for HV &
50 MΩ for LV
windings at the the
temp of 50°C.
BDV > 30 kV(avg) at 2.5mm
gap
Earth Earth resistance shall be
resistance less than 1Ω
Witnessed by:
Page 309 of 333

Annexures DT-3
Check List for Dry type Distribution Transformer: Checked
1) Check that no dust on enclosure, doors & marshalling box.
2) Check the enclosure & marshalling doors are closed properly.
3) Check for working/setting for thermostat in marshalling.
4) Check for working and physical condition of DT energy meter.
5) Check for working of lamp in marshalling box.
6) Check the no dust deposition over active part.
7) Check the earthing of the enclosure at two places with separate earthing point.
8) Check the earthing of the neutral with two separate earthing points.
9) Check for working of exhaust fan.
10) Check there should not be any open space.

Witnessed by:
Page 310 of 333

Annexures DT-4
Test Results:

Parameters Test
IR test. 1. IR value shall be

equal for all three
phases for HT-E,
LT-E, HT-LT.
2. Normally IR value
shall be minimum
100 MΩ for HV &
50 MΩ for LV
windings at the the
temp of 50°C.
Witnessed by:
Page 311 of 333

Annexures DT-5
Pre commissioning checks for oil filled Distribution Transformers: Checked
1) Check that the colour of the silica gel in the breather is blue.
2) Check the breather for any cracks, holes, transparency and oil in the oil cup.
3) Check for any signs of No arcing/pitting mark on Bus-bar & palm connector.
4) Ensure that there is no leakage of oil from gaskets, flanges, valves, radiators,
bushings etc.
5) Check that the bushing surface is clean.
6) Check the bushings for any crack or any chipping of porcelain.
7) Check the earthing of the tank cover to tank.
8) Check the condition of neutral & transformer body grounding
9) Ensure that the surface of radiator is clean.

10) Check the earthing of fencing (enclosure) with two separate earths.
Witnessed by:
Page 312 of 333

Annexure DT-6
Test Results:

Parameters Test
IR test. 1 IR value shall be

equal for all three
phases for HT-E,
LT-E, HT-LT.
2 Normally IR value
shall be minimum
100 MΩ for HV &
50 MΩ for LV
windings at the the
temp of 50°C.
Ratio Transformer turn
ratio test
MBT Magnetic Balance

test
BDV > 30 kV(avg) at 2.5mm
gap
Witnessed by:
Page 313 of 333

Annexure DT-7
Pre commissioning checks for Dry type Distribution Transformer: Checked
1) Check that no dust on enclosure, doors & marshalling box.
2) Check the enclosure & marshalling doors are closed properly.
3) Check for working/setting for thermostat in marshalling.
4) Check for working and physical condition of DT energy meter.
5) Check for working of lamp in marshalling box.
6) Check the no dust deposition over active part.
7) Check the earthing of the enclosure at two places with separate earthing point.
8) Check the earthing of the neutral with two separate earthing points.
9) Check for working of exhaust fan.
Witnessed by:
Page 314 of 333

Annexure DT-8
Test Results:

Parameters Test
IR test. 1 IR value shall be

equal for all three
phases for HT-E,
LT-E, HT-LT.
2 Normally IR value
shall be minimum
100 MΩ for HV &
50 MΩ for LV
windings at the the
temp of 50°C.
Ratio Transformer turn
ratio test
MBT Magnetic Balance

test
Witnessed by:
Page 315 of 333

Annexure RMU-1
Check list –RMU
Sub-Division
Item Description Status
A Type of Substation
B 11 kV Switchgear/RMU
1 Make
2 Physical Condition
(a) RMU Covers
(b) Earth Bus Bar Status
3 SF6 Preassure Gauge Indication
4 Voltage Indicating LED's
5 Grounding
6 Rubber Mat
7 Fault Passage Indicator
Witnessed by:
Page 316 of 333

Annexure RMU-2
Check List:
(To be filled by JUNIOR ENGINEER/Project Engineer
1) Check the manometer for any signs of SF6 gas leakage.
2) Check the functioning of the breaker, isolator & earth switch.
3) Check the functioning of FPI.
4) Check the functioning of VPIS
5) Check the Earth Resistance
6) Check the cable tightness
Witnessed by:
Page 317 of 333

Annexure UG-1
Check List during Cable Testing Checked
1. Ensure cable is not live by Neon Tester.
2. The cable earthing is properly connected to Panel earth
3. The Panel earthing is properly connected to S/S Earth.
4. Ensure Cable Terminations are cleaned properly
5. Ensure Cable cores are earthed other than testing core
6. Ensure cable testing at Recommended voltage
Check during Rectification
1. Ensure caution tape, warning lights Boards & barricading

Provided at work site
2. Ensure cable laid at recommended depth
3. Ensure docketing done on cable & joints
4. Ensure backfilling done properly
Witnessed by:
JUNIOR ENGINEER/PO: SDO:
Page 318 of 333

Annexure ABC-1
Check List
1. Ensure AB cable is not live by use of Neon Tester.
2. Ensure AB cable earthing is properly connected to Messenger
3. Ensure Messenger earthing is properly connected to Pole Earth.
4. Ensure AB Cable Terminations are cleaned properly
6. Ensure cable testing at recommended voltage
1. Ensure caution tape, warning lights, barricading

2. Ensure proper jointing done at fault sites.
3. Ensure Plastic Cable Ties are used to hold the joint
Witnessed by:
Page 319 of 333

Annexure-ERT-1
Check list- Earthing

Pre-requisite for Routine Maintenance
T&P/material/PPEs
Cotton Rag
Routine Maintenance Activities
Permissible Action
NATURE OF WORK Freq Status
Values Taken
Check and Clean
All Earth pits Twelve Months N/A
Check and Tight
All Earth connections at equipment
Twelve Months N/A
mounting frames
All Earth connections at Earth pits. Twelve Months N/A
Measurement
All Earth pits resistance for HT/LT Feeder
Twelve Months < 5 Ohm
Neutral
All Earth pits resistance Twelve Months < 5 Ohm
Resistance of Pole Twelve Months < 1 Ohm
General Checks
Check all equipments for double earthing Twelve Months N/A
Check all earthing conductors for
Twelve Months N/A
adequacy & proper tightness.
Check proper clamping of earthing pipe
Twelve Months N/A
and earthing conductor.
Check numbering of all earth pits. Twelve Months N/A
Check availability of Cast Iron lid for
Twelve Months N/A
each earthing pit.
Check exposed portion of earth conductor
Twelve Months N/A
for Galvanizing or painting
Check & ensure painting of Earth isolator
box with Green color for fast Twelve Months N/A
identification
Check that each multicore cable is
Twelve Months N/A
grounded through cable gland.
Final Status and Remarks
Witnessed by:
Page 320 of 333

Annexure- G.O.-1
Check List- G.O Switch
Sr No. Particulars Ok Not OK
1 Alignment of Male Female Contact
2 Condition of Post Insulator
3 Operating Rod
4 Earthing of G.O Switch
5 Condition of Arcing Horn
6 Condition of Operating Handle
7 Locking Arrangement
Witnessed by:
Page 321 of 333

Annexure- OH-1
Check List –OH Lines
Sr
No. Parameters Observations
1 Condition & size of GI wire. It should be 7/10 SWG OK Not OK Remarks
Condition of Guy/Egg Insulator, if any damage or
2 missing observed, should be fix/replace. OK Not OK
Condition of tension screw, if any damage observed
, it has to be changed otherwise to tighten the turn
3 buckle ,if required OK Not OK
4 condition of anchor hook OK Not OK
Visual Inspection
Condition of Disc Insulator, if there is any crack,
flash mark on the surface of the disc, disc should to
5 be change. OK Not OK
Condition of strain clamp of disc insulator, If any
6 crack or flash mark on surface, it has to be change OK Not OK
Condition of Pin insulator, if there be any flash
mark on the insulator surface, it has to be change
7 otherwise check the tightness with the spindle. OK Not OK
Condition of Pin insulator spindle, if any damage
or bend, to be change otherwise check the tightness
8 of the fixing nuts. OK Not OK
Condition of Top hamper, if any tilt observed at top
hamper it has to be straight or any damage occurred
to the metal part, it is to be change, otherwise check
9 the tightness of fixing nuts bolts. OK Not OK
Condition of the V-arm. if any damage occurred on
V-arm or on the fixing clamp, it is to be changed
otherwise check the tightness of the fixing Nuts,
10 bolts OK Not OK
Condition of channel-arm, if any damage occurred
on channel-arm or on the fixing clamp, it is to be
changed otherwise check the tightness of the fixing
11 Nuts, bolts OK Not OK
All metal part to be painted by Primer &Aluminium
12 paint for increasing the durability of life span OK Not OK
13 Visual inspection of bare conductor OK Not OK
Span length should be maximum 40m /50 m (Urban
14 /Rural) if the length larger than it , mid pole to be OK Not OK
Page 322 of 333

provided.
Line should be sectioned at every 4/5 span apart, if

15 more it to be reduced to 4/5 span OK Not OK
16 Visual inspection of Earthing OK Not OK
Visual inspection of Guard wire- if any
damage/broken happened, it would be drawn by 4
17 SWG GI wire. OK Not OK
Inspection of Joints – all jumpers should be done by
conductor same as line conductor or higher rating &
joints to be done by suitable C-wedge connector/ PG
Clamp/D-clamp. Mid span joint to be to be done by
Suitable Sleeves & the joint is limited to 2 no per
18 span. OK Not OK
19 Anti-climbing device OK Not OK
Witnessed by:
Page 323 of 333

Annexure LT ACB
SN Parameter Points to be checked Finding
1 Physical a) check ACB have cover and locked.

Condition b) Check for any visual deformity/ flash
mark/ crack/ dust on arc chutes, arcing
contacts and moving contacts.
c)Check the point of entry of busbars into
the enclosure (The busbars should be
properly tapes and the entry should be
sealed with sealants like silicon grease)
d) Check tripping circuit, CTs, release (
if applicable).
e) Status of Enclosure to be checked (
damage/ rusting, etc)
2 Alignment The ACBs placed on level structure and
and Support secured properly to be checked-
Structure
3 Dressing and
Crimping of
All incoming and out going cables to be
Main &
crimped and connected properly to the
Looping
incoming and outgoing busbars.
cables
4 ACB
Earthing
Earthing to be checked
5 Safeguarding Bakelite/ FRP separator plats used where

of Bare clearance are reduced are to be checked
Terminals
Witnessed by:
JUNIOR ENGINEER SDO:
Page 324 of 333

Annexure- LT UG Cable
1. Ensure cable is not live by Neon Tester.
2. The cable earthing is properly connected to Panel earth
3. The Panel earthing is properly connected to S/S Earth.
4. Ensure Cable Terminations are cleaned properly

1. Ensure caution tape, warning lights Boards & barricading
2. Ensure cable laid at recommended depth
3. Ensure labelling done on cable & joints
4. Ensure backfilling done properly
Witnessed by:
Page 325 of 333

Annexure LT OH Conductor
SN Parameter Points to be checked Finding
1 Physical a.Check the Condition & size of GI wire

Condition (It should be 7/10 SWG)
(Visual b.Check the Condition of Guy/Egg
Checking for Insulator-
Stay and c. Check the Condition of tension screw
Line support) d.Check the condition of anchor hook
e. Check the Condition of Shackle
Insulator
f. Check the Condition of Pin insulator
spindle
g. Check the Condition of Top hamper
h. Check the Condition of the Double
line X-arm
i. Check all metal part to be painted by
Primer &Aluminium paint
2 Conductor j. Check if any damage occurred on the
Inspection conductor
k. Check for use of Line Spacer
l. Check for use of cradles
3 Earthing check for proper earth wire &Earthing
4 Joints & check for proper Joints and Jumpers

Jumpers
5 Pole i. Check for Cable mounting on over head
Connections feeder
ii. Check for no of service cable form one
single pole & dressing of service cable
6 Configuratio Check for configuration of Line-

n of Line
Vertical Configuration
Delta Configuration
Witnessed by:
Page 326 of 333

Annexure LT ABC
1. Ensure AB cable is not live by use of Neon Tester.
2. Ensure AB cable earthing is properly connected to Messenger
3. Ensure Messenger earthing is properly connected to Pole Earth.
4. Ensure AB Cable Terminations are cleaned properly
7. Ensure caution tape, warning lights, barricading

provided at work site
8. Ensure proper jointing done at fault sites.
9. Ensure Plastic Cable Ties are used to hold the joint
Witnessed by:
Page 327 of 333

Annexure LT Earthing
Name of LT Feeder: Date & Time

Pole No-
Season - Summer/Winter:
Pre-requisite for Routine

Maintenance
T&P/material/PPEs
Cotton Rag
Routine Maintenance Activities
Permissible Action
NATURE OF WORK Freq Status
Values Taken
Check and Clean
Twelve
All Earth pits N/A
Months
Check and Tight
All Earth connections at equipment Twelve
N/A
mounting frames Months
Twelve
All Earth connections at Earth pits. N/A
Months
Measurement
All Earth pits resistance for LT Feeder Twelve
< 5 Ohm
Neutral Months
Twelve
All Earth pits resistance for LT ACB < 5 Ohm
Months
Twelve
Resistance of Pole < 1 Ohm
Months
General Checks
Check all equipments for double Twelve
N/A
earthing Months
Check all earthing conductors for Twelve
N/A
adequacy & proper tightness. Months
Check proper clamping of earthing pipe Twelve
N/A
and earthing conductor. Months
Twelve
Check numbering of all earth pits. N/A
Months
Check availability of Cast Iron lid for Twelve
N/A
each earthing pit. Months
Check exposed portion of earth Twelve
N/A
conductor for Galvanizing or painting Months
Check & ensure painting of Earth Twelve N/A
Page 328 of 333

isolator box with Green color for fast Months
identification
Check that each multicore cable is Twelve
N/A
grounded through cable gland. Months
Final Status and Remarks
Witnessed by:
Page 329 of 333

Annexure LT Metering & Service Cable
Date &
Name of Consumer: Time
Account No-
Sub-Division -
Permissible Action
NATURE OF WORK Frequency Status
Values Taken
Any visible Cut mark or Puncture on
24 Months N/A
service cable
Checking all required information
24 Months N/A
written on meter box and are visible.
Whether Meter/MCCB is tightly fixed
24 Months N/A
or hanging
All Seals on MCCB & Terminals are
24 Months N/A
proper and not tampered
Consumer cable is at adequate height
Min 5.8
while crossing the street/road (from 24 Months
Meters
ground)
Accuracy of Meter 24 Months ±3%
Witnessed by:
Page 330 of 333

Annexure LT Feeder Pillar
Name of Feeder Pillar Date

Type of Feeder Pillar Time
Feeder Name
Permissible Action
Values Taken
Cable connection tightness 12 Months N/A
Replacement of sockets 12 Months N/A
Tagging of outgoing & incoming
12 Months N/A
feeders
Earthing of Feedar& Service
12 Months N/A
Pillar (values to be provided)
Proper Cable earthing 12 Months N/A
Locking of doors 12 Months N/A
Replacement of fuse 12 Months N/A
Replacement of fuse base 12 Months N/A
Cleaning of Feeder Pillar 12 Months N/A
Condition of Plinth 12 Months N/A
Danger Plate 12 Months N/A
Witnessed by:
Page 331 of 333

Annexure LT Fuse Board
Name of DT Date
DT Rating Time
Feeder Name
Permissible Action
Values Taken
LV cable from DT shall be routed
12 Months N/A
through palm/bi-metallic connector.
Insulated cable from DT to fuse board

12 Months N/A
shall pass through DT meter CTs rings.
Only insulated cable shall be used for

connecting LV side of transformer to 12 Months N/A
fuse board.
Laying of cable from LV side of DT to
fuse board shall be separated using cleat 12 Months N/A
(wooden/PVC).
Proper size thimbles/Lugs used at cable

12 Months
end to join it to fuse board. N/A
Lugs/Thimbles shall be fixed using

proper size crimping tool (hammering of
Lugs/Thimbles must be avoided because 12 Months
N/A
this leads to weakening/breaking of
strands of cable).
Proper color tape being used for taping

12 Months N/A
at lugs/thimbles.
Fuse Board shall be installed on
12 Months N/A
Bakelite sheet.
Height of fuse board 12 Months Min 6 Feet
Check for tightness of fuse wire. N/A

12 Months
Check for any oil & dust from fuse wire

12 Months N/A
and aluminum parts
Page 332 of 333

Only insulated cable shall be used for
12 Months N/A
connecting fuse board to feeder line.
Laying of insulated cable form fuse

board to feeder line shall be properly
12 Months N/A
routed using clamps to fix it from
hanging.
Measurement of load of LT side of DT As per rating
12 Months
(Phase wise) of DT
R Phase
Y Phase
B Phase
Fuse wire Detail
Size
Rating (Amp)
Witnessed by:
Page 333 of 333

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Maintenenace Manual 23.01.17

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Draft Manual for Maintenance of

Distribution network, under DHBVN

Name of Zone Name of District

 Maintenance is defined as the combination of all technical, administrative and managerial

Details of these type of maintenance strategies are given below.

 Low Maintenance Cost

 As no Maintenance is done until the equipment is Fails / broken

 Less Manpower / Staff members required

 As no Maintenance is done until the equipment is Fails / Broken

 As maintenance is done on equipment only when it fails and fails are

 Difficult to control budgets

 Increased cost due to unplanned downtime of equipment, unsafe

 Low component life cycle or Shorter life expectancy of assets

 Reactive maintenance does not keep the systems running in optimal

 When work is scheduled, technicians have time to review the

 Reactive repairs tend to take longer due to a number of factors

 Irregular equipment downtime

 Planned maintenance can be written into the production schedule

 Technicians spend time running around looking for the correct

 Interferes with planned work

 Emergency repairs are usually prioritized at the expense of planned

 A minor issue could quickly into a major system repair. I personally

 Unplanned downtime can lead to late orders if equipment cannot be

 Reactive maintenance does the bare minimum to get the system up

Preventive maintenance can be defined as follows: Actions performed on a time- or machine-run-

Preventative maintenance is planned so that any required resources are available.

 Due to Timely & proper Maintenance of Equipment. As Overall Life

 Due to Timely & proper Maintenance of Equipment. As Overall Life

 Estimated 12% to 18% cost savings over reactive maintenance program.

 In case of Reactive Maintenance, due to lack of proper maintenance,

 Cost effective in many capital intensive processes.

 Increased cost due to unplanned downtime of equipment, problems moving

The advantages of predictive maintenance are many. A well-orchestrated predictive maintenance

 Increased component operational life/availability.

 Increased investment in diagnostic equipment.

Reliability Centered Maintenance

 Significant initial costs for training, and equipment.

SLD OF 33/11KV SUBSTATION

Low Oil Level

POWER TRANSFORMER USED IN DHBVN

MAIN PROTECTION OF POWER TRANSFORMER:

BACKUP PROTECTION OF POWER TRANSFORMER:

This relays shall have the following function:

Normally, as a cost effective , we are considering Biased differential protection in addition to

General Supervision for conservator:

 Visual Check for Conservator Oil Level

TESTS OF POWER TRANSFORMERS

 Magnetic Balance Test.

 Vector group test ( for Dyn11)

MEASUREMENT OF WINDING RESISTANCE

 To calculate I2R loss of the winding.

 IS-2026(Part 1)-1977-Clause 16.2

Dos and Don’ts:

TRANSFORMER TURN RATIO

 To measure the turn ratio of the power transformer.

1 TRM PWR3A 110 volt 0.03

2 Multimeter 0-1000 volt +/- 0.5

Dos and Don’ts

 To ensure proper dryness of all active parts.

 De- energize , discharge the equipment which is to be tested as a safety precaution

Tan delta can be taken in three methods

 GST mode ("Grounded Specimen Test")

Tan Delta (Dissipation factor)

II. Induction heating recommended.