MH/HTSWGR/EP/01/R0

ERECTION PROCEDURE FOR

6.6 KV /11 KV SWITCH GEAR Page 1 of 6

1. SCOPE:

This procedure covers the guidelines for 6.6 KV/11 KV Switch Gear receipt, handling and
installation for all applicable areas of LITL electrical package.
2. PURPOSE:

The purpose of this procedure is to provide guidelines for receipt, handling and installation of 6.6
KV /11 KV Switch Gear in all areas of plant.
3. APPLICABILITY:

This procedure is applicable for all the 6.6 KV /11 KVI Switch Gear used at UPCL.
4. REFERENCE DOCUMENTS:

1) Module specifications
2) Applicable codes and specifications.
2) Equipment layout drawings.
3) Manufacturers scheme drawings & dimensional drawings.
4) Manufacturers instruction for erection & Pre commissioning activities.
5. RESPONSIBILITY:

Responsibility of implementation of this procedure lies with GET Site In Charge

6. PREREQUISITES:

a) Approved drawings shall be available for erection of 6.6 KV /11 KV Switch Gear
b) Get area clearance for equipment erection.
c) The civil embedded plates for panels shall be checked with respect to approved GA drawings
d) Required no. of 6.6 KV /11 KV Switch Gear with all its accessories shall be available at site .
e) Route and feasibility of panel shifting and lifting shall be surveyed thoroughly.
f) Ensure that proper security arrangement / lockable door is provided before Energisation.
g) Proper Ventilation and illumination shall be available during the time of erection and other
activities.
h) Qualified manpower for erection shall be employed.
i) Approved procedure for welding and structural steel fabrication & erection shall be followed.
j) Welding consumables shall be of approved make.
k) Use Safety tested tools and tackles shall be ensured.
l) Release note along with Material receipt intimation cum acceptance report shall be ensured.
m) The Energized Power Distribution Board shall be available at site.

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7 EQUIPMENT & ACCESSORIES:

a) Rolling pipes / Skid Rollers/ Crowbars.

b) Electrician tools.
c) Spanner sets.
d) Welding machine & all accessories
e) Slings and ropes as per requirement.
f) 500V, 2500 V Megger.
g) Torque wrench.
h) Crane, Motorised winches, Trailers/trucks and vehicle for equipment shifting.
8.0 PROCEDURE

8.1 RECEIPT OF PANELS ACCESSORIES :

a) Panels and accessories received shall be checked with respect to packing list, BOM, release &
test certificates.
b) Any damages observed in the consignment shall be brought to the notice of transporter and
supplier for immediate replacement.
c) Minor damages if observed shall be repaired / replaced with the approval of Manufacturer and
Engineer In Charge.
8.2 SHIFTING OF MATERIALS FROM STORAGE YARD TO ERECTION SPOT
a) Verify the route from unloading spot to erection spot for free access
b) Load the panel in truck from storage yard using a mobile crane .
c) Ensure correct panel is received from the stores and it is being taken to its designated location /
Position.
d) After loading the switchgear cubicle on the truck, tie them to sides of truck firmly by rope.
e) After reaching the point nearest suitable to erection spot, unload the cubicle of the switchgear.
f) For switchgear to be installed at higher elevations shift them from unloading bay to higher
elevation by using a crane/ Winch / chain pulley blocks, through the openings planned in the
building for the purpose.
g) Shift the panels by putting skid rollers/pipe rollers under the bottom of wooden base pallet &
pushing the panel manually up to the erection spot. Ensure that the panels are not given any
undue jerks. Also ensure the safety of working personnel are as per the approved safety
procedures.
8.3 BASEFRAME ERECTION FOR 6.6 KV /11 KV SWITCH GEAR
a) Check the location, dimension, and clearances as per the GA drawing.
b) Base frames shall be properly identified with respect to their designated panels before
positioning.
c) Clean the EPs with buffing wheel , then Place the base frames on the EPs with respect to grid
reference & clearances shall be checked. Check the level of base frame with water level after
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placing on the EP's. Provided MS plate / Shims packing as required to achieve uniform level
between EP and the base frame. The base frame shall be checked for leveling and alignment. If
deviations are observed it can be corrected with shims. Tolerance Limit + / - 3mm is allowed.
Remove the paint from base frame surface wherever it is to be welded to EP.
d) After ensuring the proper leveling, tack welding shall be carried out between EP's and including
packings if any, with the Base frames. After tack welding of all base frame with EP's check the
final leveling.
e) After ensuring alignment of all panels (Final Stage), full welding shall be carried out as a final
stage between base frame and EPs. Size of the fillet weld shall be 6 mm. Welding shall be
carried out as per approved welding procedure.
f) After completion of erection, all welded areas of base frame shall be touched with black enamel
paint
8.4 6.6 KV /11 KV PANEL ERECTION
a) Unpack the transported units of switchgear panel and remove the wooden packing from sides
and top except on the bottom side (Base). Bottom pallet shall be removed only when the switch
gear nears to its location. Dispose the wood to its allocated area. Check the nameplate details
and for any physical damage.
b) Check the two diagonal distances of cubicle to ensure that frame is not damaged. Difference
between two diagonal distances should not be more than 6 mm .
c) Shift the switchgear panels on to the welded base frame. Shifting of panels shall be done with
Rollers / Pipes / Skid Rollers / Crow bars. If crow bar is used, it shall be inserted on the either
side or rear of the cubicle for shifting. Crow bar should never be inserted in the front of the
panels. Check for front view, Straightness, side alignment, leveling and sequence (board
number, breaker number etc.) of switchgear it should match with the GA drawing.
d) Panels in sequence shall be erected one by one.
e) Fasten the adjacent switchgear panels with fasteners and accessories (loosely supplied)
f) Now check for alignment of panels. For Alignment, first panel shall be taken as reference and
remaining panels can be checked with respect to that by means of water level / Plumb .Any
deviations observed in the alignment shall be adjusted with shims of proper size.
g) Verticality of panel shall be checked for all panels by means of plumb.
h) After ensuring for horizontality and verticality inter panel bolts shall be tightened fully as per
Manufacturers recommendation.
i) Tack weld switchgear panel to base frame as per enclosed GA drawing at the both front and rear
sides of each panel.
j) Clean the contact surface of the phase, neutral and earth busbars at the sides of each
switchgear and apply electrical contact grease on their surface. Cleaning of bus bar joints shall
be done with cleaning aid acetone. For Bus bar Joints made at white petroleum Jelly shall be
applied. Couple the bus bars of adjacent switchgear units with busbar links and necessary
hardware with proper alignment and clearance as per the drawing.
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k) Tighten all the bus bar joints, fasteners using torque wrench. Torque wrench set shall be 40 Nm
as per manufacturers recommendation .Tolerance shall be of +/- 10 Nm
l) Now full welding of 6 mm between HT Panels and Base frame shall be carried out. The length of
welding and gaps between welding shall be decided on case to case basis.
m) Ensure also that earth busbars are properly connected and tightened Tightness of Bolts M12
Bolt 40 – 50 Nm (+/- 10 Nm )
n) Provide earthing to switchgear as per earthing scheme and drawings
o) Terminate all the inter panel wiring between adjacent switchgear panel as per the
interconnecting schedule.
p) Core of all CTs shall be connected to the respective Phase Bus.
q) Install all loosely supplied meters, relays, instruments as per GA drawing .
r) After completion of all erection activities, Cleaning of insulators, bushings, bus bar joints etc shall
be done with CRC –26 / Acetone .
s) Install the shrouds at all the bus bar joints.
t) IR Value of HT Switch Gear shall be done with 5 KV Meggar as per the enclosed format .
Recommended Meggar and Minimum IR values in dry atmospheric Condition are as
below:-
Voltage Meggar IR value (Min)

1 KV to 33 KV 5 KV 100 M. Ohms .
If the test value is less than the above, arrange drying out for switchgear.

u) After completion of all checks panels shall be cleaned fully by Hot blower.
PROCEDURE FOR CONDUCTING VARIOUS PRELIMINARY CHECKS ON 6.6 KV Cl-III
SWITCHGEAR
A) Switch Gear Preliminary Checks :
1) Check name plate details of every associated equipment according to specification.
2) Check for any physical damage .
3) Check for tightness of all bolts , clamps and connecting terminal.
4) Check for panel cleanliness
5) Check for cleanliness of insulators and bushings .
6) Check space heaters are provided in all compartments with thermostat .
7) Check the clearances between phase to phase & phase to earth.
B) Circuit Breaker preliminary checks:
1) Check nameplate details according to specification.
2) Check for any physical damage.
3) Check for proper earth connection.
4) Check cleanliness of insulators and bushings.
5) Check for all moving parts for proper lubrication.
6) Check for proper movement of breaker from with drawn position to test and test to service and
vice versa.

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7) Check for proper engagement of secondary plug and socket.

8) Check for proper engagement of earthing contacts.
9) Check for indication lamp & Selector Switches.
10) Check for proper engagement of tulip finger contacts with the cubicle contact bolts.
11) Check alignment of breaker trucks for free movement inside the cubicle and correct operation of
shutters.
12) Check for interchangeability of Circuit breaker of same rating.
13) Check for free operation of doors for circuit breakers and its mechanical interlock when breaker
is kept in Service / Test / Isolated Position.
14) Perform manual closing, opening operation on CB. Confirm the operation of mechanical
operation indicators. Note down any deficiency observed.
9. ACCEPTANCE CRITERIA:

a) Conformity to schedule, drawings & specifications and manufacturers instructions.

10. CHECK LIST

a) The following checks has to be done as per the erection procedure.

Sl.No. Procedure number Description
1. Installation of 6.6KV CL-III SwitchGear
Insulation resistance on busbars for 6.6 KV CL-III
2.
SwitchGear
3. Insulation resistance test on CB
Physical check for clearance between bus bars for
4.
6.6 KV CL-III SwitchGear.

11. PRECAUTION:
a) Check the physical conditions of switchgear board before shifting from stores.
b) Qualified workmen shall be used for shifting and erection of 6.6 KV switchgear board.
c) While transporting in the truck switchgear board shall be tightened and wooden packings shall
be provided .
d) Safe PP ropes shall be used for shifting the switchgear board .
e) Discharge the bus after conducting IR test with discharging rod connected to the earth
f) Ensure safety of operating and testing personnel while conducting IR test. Rubber mats of 6.6
KV grade should be provided along the panel as per drawing.
g) Do not over tighten the busbars above its specified torque value.
h) Do not use tools other than panel keys (Such as screwdriver etc) for opening doors.
i) Do not erect panel on uneven foundation, as this will cause misalignment of horizontal busbar at
transport section.
j) Do not store panel in open and humid areas.
k) Do not send panels to erection spot with out inspection of transport damage.
l) Do not leave doors / blank cut out if any in open condition.

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12. RECORDS

a) Manufacturers test reports for switchgear board shall be available.

b) Erection checklist No.______________ SwitchGear
c) Calibration certificate of testing instruments shall be available.

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