SCOPE OF WORK FOR SUPPLY ERECTION,

TESTING & COMMISIONING OF EV BUS

BMTC Kempegowda BUS DEPOT.

Prepared By Darshit Vyas 27/04/2022 Version.00

 INDEX

General Introduction – CHARGE+ZONE.......................................................................................................3

INTENT OF SPECIFICATION..........................................................................................................................3
Depot Location............................................................................................................................................4
SCOPE OF WORK (General).........................................................................................................................4
SCOPE OF WORK (Civil Services).................................................................................................................5
SCOPE OF WORK (Electrical Services)..........................................................................................................7
Safety..........................................................................................................................................................8
DEVIATIONS..............................................................................................................................................10
Penalty......................................................................................................................................................10
Equipment Methodology of Erection/Testing/Commissioning work........................................................11
Transformer..............................................................................................................................................11
STORAGE, HANDLING & INSTALLATION PROCEDURE OF HV/LV Switch Gear Panels................................19
RMU..........................................................................................................................................................22
LT PANEL...................................................................................................................................................28
Cables........................................................................................................................................................33
Method for Bus Duct Installation & Testing..............................................................................................37
Grounding and Earthing............................................................................................................................40
General Introduction – CHARGE+ZONE

TecSo Charge Zone (P) Ltd. serves charging needs of EV users. Company provides a hassle free and
reliable charging services for all types of Electrical Vehicles (EVs). They are part of TecSo Global
group, a leader in Renewable Energy Solutions in India, Product Development and Software
Engineering.

The key strength of the group is in the area of Technology, Government Regulations, Power Purchase
Agreements, CAPEX and OPEX model of Solar Power Plant and in Electric Vehicle Supply Equipment
including electrical infra

INTENT OF SPECIFICATION

This specification broadly describes the scope of work/ services regarding electrical and associated civil/
structural work for supply, installation, testing & commissioning of EV Infra.

Although such items of supply and/ or installation might not have been described in the specification,
the Bidder shall supply anything and everything to complete the project within batter limits.

This specification shall be read in conjunction with all documents, standards, Annexures and other
relevant reference material as specified herein.

The EV INFRA shall be installed and commissioned in existing allotted location. Therefore, before
quoting, the bidder shall visit site and make themselves familiar with the work actually involved and
actual site conditions. Failure to do so shall not absolve the bidder of their responsibilities based on
adverse site conditions.

The work shall be done in full compliance of the statutory requirement of Govt. Of India, State Govt, IE
Rules etc.

It will be the responsibility of Bidder to depute duly qualified personal to carry out design & detailed
engineering, erection, testing & commissioning.

The supervisors deployed shall be in possession of valid certificate of competency issued by competent
authority to supervise the job which is assigned to them. Similarly, the workmen deployed shall be in
possession of valid certificate of competency issued by competent authority to carry out the job which
is assigned to them. Copy of all such certificates of competency shall be submitted to engineer-in-charge
and original shall be shown on demand.

Preparation & Submission of test reports and co-coordinating for inspection and clearances from
CEIG /State Electricity Authorities as required shall be under the scope of the Bidder.
Depot Location

Kempegowda Bus Depot , Bengaluru

SCOPE OF WORK (General)

The scope of work/ services shall comprise:

COORDINATION WITH STATUTORY BODIES & OUTSIDE AGENCIES

The bidder shall be fully responsible for carrying out all co-ordination and liaison work as
required with Electrical Inspector.

The application on behalf of CZ for submission to the Electrical Inspector along with copies of
drawings complete in all respects shall be done by the bidder & approval / certificates shall be obtained
by the bidder well ahead of time so that the actual commissioning of equipment is not delayed for
want of inspection and approval by the inspector & statutory bodies. The bidder shall arrange the
actual Inspection work by Electrical Inspector.

ELECTRICAL POWER & WATER FOR CONSTRUCTION

Electrical Power Supply will be available near one point, Bidder has to arrange extension of power at his
own tools and units for Necessary commissioning /Testing/ Erection Work.

Water for construction purpose shall be arranged by Vendor

SCOPE OF WORK (Civil Services).

CODES AND STANDARDS

All standards, specifications, acts and code of practice shall be followed. In case of conflict between this
specification and those (IS standard/ IRC specification/CPWD Specification, etc.) referred to herein, the former
shall prevail

General requirement
The work shall be carried out according to the design / drawings to be developed by the TCZ &
For all foundations etc. necessary layout and details shall be Provided by the TCZ keeping in view
the functional requirement of the Sub-Station. Certain minimum requirements are indicated in this
specification for guidance purposes only. However, the Contractor shall quote according to the
complete requirements.

The Contractor shall take all necessary precautions to protect all the existing equipment’s,
structures, facilities & buildings etc. from damage. In case any damage occurs due to the activities
of the Contractor on account of negligence, ignorance, accidental or any other reason whatsoever,
the damage shall be made good by the Contractor at his own cost to the satisfaction of the TCZ
Engineer. The Contractor shall also take all necessary safety measures, at his own cost, to avoid any
harm / injury to his workers and staff from the equipment & facilities of the power station.

During the progress of work, the Engineer will exercise supervision of the work to ensure that the
technical provisions of the contract are being followed and the work is being executed accurately
and properly. However, such supervision shall in no way relieve the Contractor of the responsibility
for executing the work in accordance with the specifications.

Before submitting the bid, the Contractor shall inspect and examine the site and its surroundings
and shall satisfy himself as to the nature of the ground and subsoil, the availability of materials
necessary for completion of the work, means of access to site and in general shall himself obtain all
necessary information as to risks, contingencies and other circumstances which may influence or
affect his offer. No extra claim consequent on any misunderstanding or otherwise shall be allowed.

Excavation and Backfill

Excavation and backfill for foundations shall be in accordance with the relevant code.
Whenever water level is met during the excavation, it shall be dewatered and water level shall be maintained
below the bottom of the excavation level during excavation, concreting and backfilling. Nothing extra shall be
payable by the owner on this account.

Compaction

The density to which fill materials shall be compacted shall be as per, relevant IS and as per
direction of Owner. All compacted sand filling shall be confined as far as possible.

The thickness of fill material under the foundations shall be such that the maximum pressure from
the footing, transferred through the fill material and distributed onto the original undisturbed soil
will not exceed the allowable soil bearing pressure of the original undisturbed soil. For expansive
soils the fill materials and other protections etc. to be used under the foundation has to be
approved by the Owner.
Plastering

All internal walls shall have minimum 12mm/ 15mm thick 1:4 (1 Cement: 4 fine Sand) cement sand
plaster. The ceiling shall have 6mm thick 1:3 cement sand plaster.

Finishing

All external surfaces (control room building and boundary wall) shall have stone grit/ Marble Chips with colour
pigment (with groves formed) (item no.13.72-DSR 2012) finish over 12mm thick cement sand plaster 1:4 (1
cement: 4 coarse sand) mixed with water proofing compound in the ratio as recommended by the manufacturer.
Suitable pigment shall be added to render the surface aesthetically pleasing as per directions of Engineer-in-charge.

DEVELOPMENT OF SWITCH YARD

The Contractor shall furnish all labour, equipment and materials required for complete performance
of the work in accordance with the drawings, specifications, and direction of the Owner.

Foundation work as per provided drawings to be done by contractor of following equipment,

 Transformers
 HT Panels
 LT Panels
 Bus Duct
 Switchyard Fencing
 Firewall
 Excavation of trenches

Specifications are to be provided for foundation in accordance with the drawings.

Stone spreading shall be done in the Outdoor Sub-Station Yard area, Distribution Transformer, HT Panel, LT Panel,
Bus Duct, Fencing and wherever equipment and structures are to be provided under the present scope of work

BOQ & Drawings

Drawings for foundation design will be shared by TCZ, Vendor has to quote accordingly, all civil items will be
procured by vendor.

SCOPE OF WORK (Electrical Services).

Erection, testing & commissioning at works.

Equipment/Material/Accessories shall be Stored at site as per recommendation of manufacturer/

supplier/ direction of supervising engineer, transportation to workplace until required for erection.

Supply, Erection, testing, and commissioning of complete system required for Installation of

 This Major Equipment’s only include Erection, testing and commissioning.

 All the Major Equipment shall be installed & commissioned as per the SLD & Plant Layout
Provided by the TCZ.
 All Equipment to be installed & tested by following Methodology for Each equipment as written
in this Scope of work.
 All Equipment shall be Commissioned & Energised by following methodology written in this
scope of work.
 Civil Foundation Work of Transformers, HT Panels, LT Panels, Fencing , Firewall will be in scope
of Contractor

As per the attached BOM ANNEXURE- I Bidder has to give his quotes for this project

All other items not specified but required for proper, safe operation and completeness of the system
will be decided as per the final BOM given by TCZ & shall be followed by bidder.

Preparation of all documents Test Report will be in scope of Bidder, formats for tests/ checks to be
conducted, acceptance/ guarantee tests to be performed as required in methodology work.

The Bidder shall furnish the bar chart for complete scope of work.

The Bidder shall obtain necessary clearances/approvals from Chief Electrical inspector of Tamil Nadu/
statutory authorities as applicable for complete electrical installation.

The Bidder shall ensure that there is no delay on account of necessary clearances, so that electrical
equipment energization doesn’t suffer.

All necessary drawings, test certificates and record of site tests etc. as required by the electrical
inspector shall be furnished.
Safety

Electrical Safety

Common safety warnings

This procedure should be followed strictly. In case the necessary work permit is taken in by authorized
person, same can be returned on phone. While issuing or returning permit on phone, the code words
should be used.

Precautions to be taken while issuing permit:

It is the duty of the shift engineer or person issuing the line clear permit to ensure that the sub-station/
feeder/equipment for which the permit is being issued, should be made dead, i.e., equipment/ feeder
should be discharged and properly earthed. First, he should switch off the equipment/feeder as per the
instructions laid down. Thereafter, he should adhere to the following instructions regarding grounding
and locking of equipment:

Safety PPEs :
Personal protective equipment (PPE) are supplied to all the personnel’s working on site and even for the
personal who are temporary visiting to the site Personal protective equipment (PPE) can be classified as:

Safety Helmet
Hard hat or helmet is issued to each and every personnel working on site. It has to be worn all times at
job site.

Safety Glasses
Safety glasses are required at construction site every time debris is filled in air due to activities on site.

Hand Protection Gloves

Hand gloves are supplied to all personals to protect against cuts when handling material or
equipment’s, during cleaning operations, cutting metal studs or similar works.

Proper Clothing
Shirts, long pants and hard soul shoes, a 6-inch-high boot is recommended

Respiratory Protection
Sometimes as voluntary respiration policy dust mask is supplied, any employee looking for additional
comfort or safety while working with fiber glass, fire proofing, cleaning the floors or handling debris.

Safety Harness
The safety harness is an attachment between a fixed and mobile object and is usually fabricated from
rope, cable and locking hardware. Full body safety harness to be used as a procedure for fall protecting
system, ignorance can result in severe physical harm. Safety harnesses keep workers safe and are
helpful in freeing their hands for work even while hanging on the side of a building.

Manual Material Handling

The personnel should be aware of his weight lifting capacity and if required take the help of another
person if required instead of taking all load himself and use proper lifting techniques. Always need to
wear the safety equipment’s while working on construction site.
Mechanical Material Handling
Mechanical material handling also requires same amount of safety as in case of manual material
handling. Equipment Operator needs to take care of the weight lifting capacity of the equipment like
forklifts, cranes and other similar to avoid accidents. Ground personnel should be in machine operator’s
vision always and should be aware of the safety procedures while working around the heavy mechanical
equipment’s.

Basic Safety Precautions at Site

In any construction project for basic safety precautions to be implemented are:
 Guard rails to be installed at open scaffold areas, all openings in the building floor, in the
excavated areas, at mobile elevated platforms.
 Yellow stickers with safety notes to be pasted where necessary
 All the working platforms should be stable, properly braced, should not be overloaded and safe
for the working personnel
 All the working areas and passageways should be free from waste or debris or any of
obstruction like stored material
 The site should be clean all the times and the material should be stored safely
 There should be proper arrangement of collection and disposal of waste materials
 First aid should be available at all times on site for cuts burns or any mishaps
 Fire extinguishers to be placed on site on proper locations in case of any fire
 That should be proper lighting arrangements on the site especially when the work is carried out
during the night stand.
DEVIATIONS
The bidder shall submit the duly signed & stamped copies of all asked documents as a token of
compliance to Charge zone. Deviations (clause-wise), if any, from this specification/ applicable
standards shall be clearly & unambiguously indicated (reasons thereof) in the offer as a separate &
specific.
Deviations from the data indicated in Specification Sheet shall be shown clearly by encircling it and
indicating the revised data in Specification Sheet. In the absence of any such activities the compliance to
the clauses shall be deemed automatically.
Any and all those deviations mentioned in the offer but not brought out specifically under the list of
deviations with reason thereof, shall not be considered as deviations taken by bidder.
Any and all deviations mentioned by bidder but not specifically agreed by /CZ in writing shall be deemed
to have been withdrawn by bidder.

Penalty
In case of failure to meet the Completion schedule, 10% of total contract value of penalty is
applicable at the rate of 1% per week of the total contract value.
 Equipment Methodology of Erection/Testing/Commissioning work.

Transformer

Importance of Transformer Handling Processes

 The way a transformer is handled and the procedures that are used to receive assemble, process and
test the transformer are of fundamental importance to the long life of the transformer.
 The installation and testing of the transformer verifies its condition at the time it is ready for service as
well as forming the baseline or signature tests for all future maintenance and later condition
assessment or analysis.

General Checks Performed By Bidder when Unit Arrives

 A careful external inspection must be made when transformer arrives at site. Condition of each
package and its contents and visible parts of transformer etc. shall be checked for any damage and
recorded.
 In case of transportation of transformer in oil filled condition, oil level & leakage (if any) shall be
checked.
 In case of any damage or oil leakage beyond permissible limit, the manufacturer shall be informed
immediately.
 The unit will be inspected prior to shifting to site for any mechanical and structural damage during
transportation.
 The name plate will be checked against equipment data sheet to confirm conformity with the
approval.
 Special attention shall be paid to the condition of instruments and monitoring devices supplied loose
or installed along with the transformer.
 In case of transformer transported with oil, a sample of oil should be taken from the bottom of the
tank and tested for BDV and moisture content.
 After inspection of Transformer and approval by local authority and s, proper care will be taken to
protect the unit from dust by suitable covering, and shall further be released for the Testing &
Commissioning work.

The inspection should include:

• Removal of any shipping, blocking or temporary support.
• Examination for indication of core shifting or tank damage.
• Tests for unintentional core or core clamp grounds.
• Visual inspection of windings leads
• Inspection of in-tank On-Load Tap Changers (LTCs) including and oil level.
• Inspection of current transformers including supports and wiring harness.
• Checks for dirt, metal particles, moisture, or other foreign material.
• Any other suspected damage based on impact recorder readings.

Found Damages such as

a) Tank sides or cooling tubes dented
b) Protruding fittings damaged
c) Oil sight-glass broken
d) Bushings cracked or broken
e) Bolts lose due to vibration in transit
 f) Breather Glass or oil Cup Broken
G) MK Box Damaged
H) OLTC Shaft seal leakage or damaged

If it is suspected that the transformer has suffered material damage, suitable action shall be taken.

 Serious damages - Serious damages should be reported to the manufacturer. It is advised to wait till
the representatives of both the manufacturer and the transporter are present before lifting the core
and coils from the tank for further inspection
 Slight damages - Damage which does not appear to be serious but which indicates heavy knock should
be treated with caution. The core of the transformer should be lifted from the tank in the presence of
the representatives of both the manufacturer and the transporter and examined for any damage to
ensure that they have not been damaged. The report of this examination should be made to
manufacturer as well as' to the transporter.
 No damage - If there are no external damages, it is advisable to Leave the transformer in its tank
without making any attempt to look inside.

Guideline for Unloading & Installation

Following tools shall be arranged before starting the in the process of Unloading of transformer.

 Fork Lift /Crane/HYDRA (Appropriate tone lifting capacity), pallet mover with capacity &
arrangement in line with the Manufacturer’s recommendations required at site.
 Portable hand tools.
 Portable Drilling Machine/ Grinding Machine & Angle Cutter.
 Spirit Level
 Level Threads
 Lifting Hooks/Lifting Belt/D Shackle (Suitable Tone Lifting Capacity)
 Spanners sets
 Ropes
 Ladder/Scaffolding Etc.

Lifting Procedure to be followed by Bidder

Transformers should be lifted by the lugs or shackles provided for the purpose and simultaneous use
should be made of all such lugs or shackles in order to avoid any unbalance in lifting.

Before lifting the complete transformer it should be ensured that all cover bolts are tightened. Apart
from the main lifting points designed to take the total weight of the unit, the transformer has subsidiary
lifting points suitable for particular components only. Care shall be taken to distinguish between them.
It is advisable to use a spreader between slings so that the lift on the hooks is in the vertical direction.
The slinging angle is not to exceed 60”. Safe loads of wire ropes and the multiplying factor to be used
corresponding to the lifting angles shall be kept in view. Gunnies are used on the slings to avoid metal
contact and consequent damage to the slings.

Where it is necessary to use jacks for lifting, only the projections provided for the purpose of jacking
should be used. Jacks should never be placed under valves or cooling tubes. Not more than two jacks
should be operated at the same time. When two jacks are being operated the opposite side of the
 transformer should be firmly supported by sleepers. Jacks are also not to be left in position with load for
a long time. The transformer should always be handled in the normal upright position. During the
handling operation care shall be taken to prevent overturning.

 The transformer unloading work at site should be carried out by skilled people, under the supervision
of manufacturer’s representative.
 Unpacking and inspection of all accessories shall be carried out taking all precautions so that the tools
used for opening do not cause damage to the contents of transformer.
 Transformer will be moved by crane/Hydra using lifting lugs as per manufacturer’s, recommendation
and shall be positioned on Transformer base in plant yard.
 Avoid jerky movement of the transformer while lifting it upwards during installation
 Transformer will be off loaded to the place nearest to the installation and protected properly from
dust & environment, etc.
 Ensure all civil works are completed for the area including floor paint to carry out the installation, and
clearance is obtained from respective authorities to proceed further.
 Prior to installation, the foundation will be checked for cleanliness and level.
 Prior to start the installation, refer to the approved Plan drawings related to the area of installation
and ensure that required materials are available at site as per approved material submittals.
 If Erection work cannot start immediately due to some reasons, then accessories shall be repacked
into their own crates properly and packing list should be retained.
 It is preferable to store the main unit on its own location/foundation.
 Ensure the installation of Transformers are carried out in accordance with manufacturer’s and local
authority’s installation recommendations, requirement of applicable standards and in accordance with
recognized industrial practices and specified in project specification to ensure that installation
complies with requirements.

Storage & handling of the main unit and the accessories at site:
 The transformer Storage & Handling work at site should be carried out by skilled people, under the
supervision of manufacturer’s representative.
 The transformer shall be unloaded at site and placed on a raised platform specifically made for long
storage. The platforms should be constructed before the spare unit reaches site. The proposed
platform shall be about 1000mm above ground level for ease of shifting on trailer for any emergency
transportation.
 RTCC panels, MBs etc. are to be inspected and stored safely.
 Proper storage of all accessories shall be ensured after unpacking in line with the OEM’s
recommendation. Fragile instruments like oil level gauge, temperature indicators, etc. are to be stored
indoor.
 Any damaged or missing auxiliaries shall be reported to equipment manufacturer and insurance
agency so that the same can be investigated or shortage made up as per the GA Drawings sent by
OEM
 The transformer can also be kept in a completely assembled oil-filled condition with all the bushings
& conservator erected. In this case all the bushings as well as the main tank of the equipment should
be shorted and earthed. In case the spare transformer is stored in an area not shielded/protected
against lightening, arrangement may be made for a temporary lightening mast in its vicinity.
 Proper drainage arrangement in storage areas to be ensured so that in no situation, any component
gets submerged in water due to rain, flooding etc
 The storage space area shall be such that it is accessible for inspection; water does not collect on or
around the area and handling/transport is easy.
 All packing cases shall be kept above ground by suitable supports so as to allow free air flow
underneath.
 Ensure the materials are stored properly and there is no mark of damage or deformity of any kind
before issuing the material from site store.

Precautions to be taken
 As far as possible no work shall be done during rainy season to avoid moisture absorption by the
transformer.
 Extreme care shall be taken to prevent any foreign material from being dropped into the transformer.
Workmen having access to the interior of a transformer should empty their pockets of all loose
materials. Any spanners or other tools used shall be securely tied so that they can be recovered easily
if accidentally dropped.
 Fibrous cleaning materials shall not be used. The presence of loose fibres in suspension in transformer
oil can reduce materially its insulating properties.
 All components despatched separately shall be cleaned inside and outside before being fitted.
 If any internal temporary transportation braces are provided they are to be removed without
disturbing any permanent internal arrangements.

Safety Precautions

 The transformer should be so installed that there is no risk of anyone receiving an electric shock.
Although, with all metal parts of the metal tank bonded together and properly earthed, the tank may
be considered quite safe, yet consideration should be given to the arrangement of the connections.
With the use of cable boxes and terminal boxes or suitable bushings the terminals are well protected.
 Necessary Fire protection device is to be arranged well before starting erection and commissioning
work.

Installation Procedure to be followed

 During erection, efforts shall be made to minimize the exposure of active parts of transformer.
Moisture may condense on any surface cooler than the surrounding air. Excessive moisture in
insulation or dielectric liquid lowers its dielectric strength and may cause a failure of transformer.
 The installation will be checked by site electrical supervisor and engineer for proper placement and
orientation of Transformer.
 After final positioning of transformer, all wheels will be locked to arrest any movements of the
transformer.
 Transformer auxiliaries and instruments will be installed as per manufacturer’s recommendation /
guidance with close supervision of site Electrical supervisor and Engineer.
 HV and LV side termination shall be carried out as per approved drawings.

Cabling
 In view of economy and compactness, control and power cables are laid in the same trench; care shall
be taken to segregate them in separate racks, with the control cables effectively screened. DC control
cables, ac power circuits and instrument transformer circuits shall be segregated from one another
 All Cabling is to be done as per the design given by /CZ / .
 Supply of the Cables and necessary termination kits, Lugs, Glands other Misc. as per the BOM given by
the /CZ/.
 Material Quality Should be as per the attached appendix and technical specification sheet
Bushings

 The bushings shall be checked for any damage at the oil end as well as the porcelains, bushings shall
be cleaned thoroughly.
 The cable ferrule is fixed in position at the top of the bushing brass tube. The lower end of the bushing
shall be inspected through the inspection cover for proper sealing.
 The line connection should be tight and should not strain the terminals. Sufficient flexibility in the
connecting leads should also be provided to avoid mechanical stress on the bushing. The arcing horns
if any shall be in proper position as shown by the supplier in general arrangement drawing.

Tap Changers

 TAP Changer to be inspected by Manually Rotating in Every Tap Positions.

 Time for Complete Tap change has to be recorded for Every Step Electrically & Manually.
 Operations of OSR are to be checked manually.
 Condition of Air release Plug has to be checked.
 All Indications Circuit is to be checked after Wiring.
 The tightness of all connections on the selector switch and terminal board is to be ensured.
 Control Power Supply for Automatic Operation (AVR Module) and Motor Power Supply needs to be
given from Auxiliary panel board with necessary Control & Power cable as per the Attached APPENDIX
of Control & Power CABLEs
 Necessary Vermin Proofing is to be done of Cable gland section & OLTC Cubicle.
 Door Switch, Cubicle light, Heaters and Pad locks operations are to be checked.
 Condition of Breather need to be checked and fitting needs to be done if provided separately by OEM.
 Silica gel & Oil is to be filled in the Breather if Not provided by OEM.

Buchholz Relay

 The Buchholz is checked for correct functioning of the mercury switches by injecting air through the
test petcock when full of oil.
 The angle of inclination is also to be checked and should be between 3” and 7”.
 When Buchholz is In service the top petcock should be open and the gas release pipe should be full
with oil.
 When the gas is to be collected through the gas release pipe, initially the oil will flow out and then the
gas can be collected. Each time after removal of trapped gas from the relay, this pipe should be primed
to the full with oil. If there is any residual air left in the pipe, this would vitiate the correct analysis of
the accumulated gas.
 Wiring of Buchholz needs to checked with MK BOX and terminal blocks to be checked and tightened
for Both Alarm & Trip Logics. (Cold & Hot testing needs to performed.)

Dehydrating Breathers

 The breather pipework shall be properly cleaned.

 The oil level in the oil seal at the bottom should be filled to the correct level with transformer oil. Any
oil that might have overflown should be wiped off.
 It is to be ensured that the breathing hole at the bottom of the seal is not blocked by dirt, etc. The
silica gel to be filled into the breather shall have blue colour.
 Explosion Vent

 The temporary cover which is provided over the explosion vent flange on the tank cover, should be
removed and the explosion vent fitted with suitable gaskets, care being taken to ensure that the top
diaphragm with its gaskets makes an air-tight joint. As the top diaphragm is sent blanked from works,
the blanking plate shall not be removed till the oil level inside the transformer comes above the tank
cover.

Temperature Indicators

 The capillary tube is protected adequately to withstand all normal handling. It should not, however, be
bent sharply or repeatedly and should be supported by clips to prevent sagging. On no account it shall
be cut.
 The thermometer pocket should be filled with sufficient transformer oil to ensure good thermal
contact between the pocket wall and the thermometer bulb.
 The connection of the winding temperature indicator C.T. is made to the thermometer pocket as per
instruction given on the Terminal Board.

Current Transformers

 Great care shall be taken in handling current transformers.

 Current transformers should be kept flat at all times. If the transformer is not handled properly, it will
deform in shape resulting in an increase in excitation current.
 All C.T. secondary terminals should be short circuited or loaded before energising the transformer.
This will prevent excessive voltage developing across C.T. secondary which can damage the C.T. and be
a hazard if touched. Excessive magnetisation of the C.T. core in this manner may affect the ratio
accuracy also.

Earthing of Distribution Transformer

 Earthing of transformer is an important aspect of Distribution Transformer installation.

 As per IE rules: 61 (1) (a) and 61 (2), the neutral bushing of the transformer and the body of the
transformer should be earthed by not less than two separate and distinct connections with a minimum
of two different earth electrodes.
 In order to comply with above rule it is a customary practice to excavate three earth pits (usually 8
feet deep) arranged to form an equilateral triangle. One pit is used for connecting lightening arrestors.
The transformer neutral earthing is connected to another pit while the body earthing is connected to
third pit. These three earth electrodes are connected to each other to form earth bus at one feet
below the ground. The earth resistance of these interconnected electrodes should not exceed 1 ohm.
 Transformer Earthing shall be done as per local authority Regulation, specification and approved
drawings.

Conservator

 Make sure that all gasket joints are oil-tight and the pipework is clean and free from moisture.
 Make sure that all Main tank and OLTC section oil Gauges are in working position.
 MOG connections are to be checked
TYPICAL TESTS CARRIED OUT BEFORE COMMISSIONING

1) General inspection a) Control and relay panels, etc.

b) Junction boxes and marshalling kiosks.
c) Radiator Tap Positions
d) Check that the oil valves are open in cooling
circuit.
2) Secondary injection On all transformer a) On all transformer protection relays.
protection relays

3) Primary injection a) Tests on operation and stability of are

4) Ratio tests
5) Tripping tests (Logic Tests)
repeated at the end of earth fault relays on
high voltage side. all other commissioning
tests
b) Tests on line directional elements of high-
voltage line relays.
c) Tests on high speed neutral ammeter.
d) Tests on overcurrent relays on low voltage
side.
e) Tests on operation and stability of earth fault
relays on low-voltage side.
f) Tests on operation of standby Earth fault
relay on low-voltage, side.
g) Tests on overcurrent relay on high voltage
side .
h) Voltage compensation
a) With 415 V applied on high-voltage side,
measure the voltage between all phases on
the low-voltage side for every tap position.
b) To check phasing, measure volts :
A to a, b and c
B to a, b and c
C to a, b and c
Where A, B and C are the terminals of three
phases on high-voltage side and a, b and c
are the corresponding terminals on low-
voltage side.
c) Magnetic balance test. On Nominal Tap ,
First tap and Last tap.
d) Single Phase Magnetic Balance.
e) Transformer Turns Ratio on every Tap.
(Where data of deviations are to be mention
specific phase wise.)
f) Magnetizing current on HV side. At every
tap.
a) High voltage.
b) Low voltage.
c) Inter tripping tests.
d) Winding temperature trips.
e) Oil temperature trips
f) OSR Trip
 g) Buchholz Relay
6) Calibrate earthing resistance On Every Earthing Pit of Transformer
7) Winding Resistance a) Winding resistance on HV Side of Every Tap
RY-YB-BR
b) Winding resistance on LV Side of rn-yn-bn
8) Tan Delta and Capacitance Measurement Following Topology shall be followed
a) HV To LV UST Mode
b) LV To HV UST Mode
c) HV to GND GSTg Mode
d) LV to GND GSTg Mode
e) R,Y,B BUSHING C1 & C2 UST Mode
9) Transformer Oil Test a) All Oil Routine test of Main tank and OLTC at
NABL Lab
b) DGA Test of Main Tank at NABL Lab
10) Tap changing tests a) To check mechanism, indication, buzzer, lamp,
etc. (Electrically BOTH LOCAL/REMOTE)

11) Short Circuit Test LV has been Short circuited and current has to be
measured on both HV and LV side at every tap
12) Check transformers on a) For transformers in a bank. equal taps before
switch
b) For transformers in paralleling

13) Insulation tests a) On high and low voltage windings.

b) On current and voltage transformers, circuits,
etc.
C) PI is to be taken for HV & LV windings
HV to Gnd, LV to Gnd, HV to LV

Commissioning of Distribution Transformer

Before actually charging the transformer the following points should be checked:
1. Transformer should be inspected by authorized electrical inspector and get permission to energize the
same
2. Oil sample need to be sent to any NABL accredited oil laboratory for testing. The pre commissioning
tests shall be carried out and the test results are to be forwarded to the OEMs and observations /
comments are to be recorded.
3. Insulation resistance and continuity of the winding should be checked by 5KV for HV & 1 KV for LV
Megger
4. Check dielectric strength of the transformer oil by taking out sample
5. Check oil level in conservator tank, colour of silica gel in the breather and oil level at the bottom of the
breather
6. Make Breaker/MCCB/Main Switch in the LT Panel OFF and charge the transformer on no load by using
DO fuse elements of suitable capacity.
7. Wait until noise of the transformer stabilizes then measure the secondary voltages phase to phase and
phase to neutral
8. Apply load on the transformer (preferably a 3 phase motor) and check direction of rotation of motor.
If the motor rotates in reverse direction, then the phase sequence of connections is wrong and needs
to be rectified. To rectify this, interchange the cable connections at the MCCB / Main switch e.g. R&Y
or Y&B or B&R phase connections. The phase sequence will then be rectified.
 STORAGE, HANDLING & INSTALLATION PROCEDURE OF HV/LV Switch Gear Panels

All Panels are to be installed and commissioned with suitable tests as directed in this methodology
and should not deviate any Standard norms and grid Code.
This method of statement describes the procedure for safely, storage , Shifting & handling as per
specification and as per the standard Practice and Code.

Equipment & Tools Required for Erection & Commissioning HV/LV Switch Gear Panels:

 The equipment that will be engaged for Installation of Panel

 Tool Box with Screwdriver, Pliers, Spanner , Hammer
 Drilling Machine with various Bits , Grinding & Cutting Machine
 Electrical Tester , Continuity Tester ,Multi Meter , Earth Tester , IR Tester, Clip on meters
 Wire Cutter , Blower ,Crimping Tools
 Knockout punch and Flat File
 Marker, Measuring tape, Level gauge / Spirit level.
 Ladder / Scaffolding / Mobile scaffold
 Chain Block and Pipe Wrench
 Portable Lights
 Removable Barricades

Storage & Material Handling :

 Suitable lockable storage shall be made on Site.
 The storage area must be free from dust and Water leakages / seepages.
 Panels and its Accessories shall be unloaded with care in designated area of the Store to avoid any
damages and against the effects of weather or any construction activities of Site.
 The Material will be stacked / unload in the site store on a proper stand on wooden loft on a flat
surface at a sufficient height from Ground.
 Materials shall be stored in a place free of water and adequately covered to avoid any kind of
damages.
 Proper protection should be given to the material by means of covering the material with Tarpaulin
sheet etc.
 If they are dispatch in packs or pallets, each pack of pallet shall be lifted individually with suitable
lifting equipment.
 The material shall be transported / Shifted in their original packing to Site location.

Sequence of Installation Works:

(1) Shifting of Panel on Site

 Prior to commencement of Panel installation works, areas and access shall be checked and
confirmed by Authorised Engineer, that they are in a suitable Condition for installation works.
 Decide appropriate Size of Crain / Hydra according to weight of Panel.
 Panel shall be carefully unloaded or shifted to the site by using Crane/Hydra or by sufficient
manpower and moved to a defined installation location.
 Remove the packing and ensure that the panel is free from transportation damages
 Check The shop drawings, Material submittals, Method statement, ITP of Manufacturer.
 Ensure all contents are available inside the panel.
 Ensure control wiring identification shall be correctly done.
(2) Installation of Panels:

 Marking of Panel Position: outdoor panel, the exact location of the panel and fixing holes to be
marked on the concrete plinth for the installation.
 Remove the Factory packing and ensure that the RMU panel is free from transportation damages
 Install the panel in proper alignment and fix properly.
 To secure panel base to the floor using M12 anchor bolts.
 Access around the panel to be checked for future maintenance as per regulations.
 Ensure the services contains water is away from the panel or properly protected against any
accidental leakages.
 Incoming and outgoing cables shall be marked/identified as per approved shop drawing.
 Mark the fixing position of the Panel’s support as per approved manufacturer drawing and
coordinate with other equipment and services.
 After marking are then drilled according to the selected sizes of anchor bolts to appropriate depth as
per approved shop drawing.
 Locknuts on the anchor bolts will ensure a permanent fixing of the Panel support to the Foundation.
 All floor mounted arrangement will be in accordance with approved shop drawings and the
approved material submittal.
 The height of panel shall be maintained as per approved shop drawing so that easy access for
termination of cables and other maintenance work can be carried out.
 Check the position according to the approved shop drawings.
 Check & ensure adequate space is available for maintenance
 After installation, the panel shall be properly cleaned and protected to prevent dust &
contamination.
 Before beginning installation in any area, examine all adjoining works in that area should be
completed. Installation shall not proceed in that area until such conditions are corrected by the
bidder.
 Fix all equipment independently of wiring system. Use cadmium of zinc electroplated bolts, nuts,
washers and screw.
 Ensures that clearance in front of switchgear is not less than 1m, or as per the drawings.
 To set up the chain block support to fix the chain block.
 When the panel reaches the actual installed location, lifting-up of panel by using of chain block. Lift
the panel on the panel base
 Necessary Termination methodology to follow as per the instruction of manufacturer
 Cable termination of every section should be done by an expert and should be in line with proper
phase sequence.
 Necessary Canopy is to be mount and erected as per instruction manual of manufacturer.

 If Panel is in section wise

 Position the first section panel on the fixing channel & check the levelling by using the level bar &
adjusting with liners.
 To secure panel to the panel base using M12 anchor bolts.
 To rack in the correct breaker & PT to the correct panel.
 Proceed in the same manner for the second sections.
 Position the second section next to the first panel.
 Secure the second section to the panel base using two M12 anchor bolts
 Interconnect & fasten the two section units together.
 Proceed in the same manner for the other sections.
 RMU

Inspection of RMU:

 Check the reference of delivered material against approved submittal and purchase order.
 Check The Material according to its Type, Size, Make
 Check for Damage/Defects to the body or fuses
 Check Quality For Paint Work
 Check Tightness Of All Bolted Connections (by Torque wrench method)
 Check That All Grounding Are Securely Connected
 Check the interlock system
 Ensure that the earth system is completed as per design drawings (correct size of earths use),
and that the grading ring is installed, undamaged and connected to the HV earth bar
 Check that the switchgear is numbered and labelled correctly.
 Check that the gas pressure is sufficient (if applicable record reading).
 Check the alignment of face plate and operation of the interlocks.
 Inspect labels, markings, safety signs and safety devices.
 Check the conditions of all Metering equipment’s and general wiring
 Check Continuity of Main, Auxiliary, Earthing and Neutral Busbar with respect to incomer and
outgoing Circuits.
 Check the connections for conformity with the reference drawings and their tightness.
 Number terminals, cables and component parts to correspond with manufacturer have certified
drawings.
 Ensure that vents are clear and filters are in place. Screens covering ventilation openings should
be in place to prevent entry of rodents or small animals.
 Check the outer appearance (absence of any traces of shocks, peeling paint) -carry out any
touch-ups if needed.
 Check that it is not possible to come into contact with energized equipment when working on
the system.
 If there are any Correction or modification than Check All internal connections/modification will
be carried out by the Manufacturer.
 Check the main bus bar and auxiliary circuits (control, monitoring, alarm, and fault) for
continuity.
 All breakers (incoming/outgoing) shall be in “OFF” position and to be locked to prevent
mishandling
 Check that the panel hinged doors are connected to the frame by earthing braids.
 Physical Damages Inspection:
 In case of any damages observed during inspection, the concern report will be issued and
Material shall be returned to the supplier for replacement.
 Fully tight all Bolted electrical connections of Electrical Switch gear of Panel.
 Check for Loose bolted electrical connections. It can lead to higher energy consumption and
eventual equipment failure if not properly addressed.
 Check for Loose control, Power wires can lead to spark, over heat which turns in to catastrophic
failure.
 Check that all wiring connections are tight and that wiring is secure to prevent damage during
routine operation of moving parts, especially when removing draw-out circuit breakers or
opening and closing cubicle doors.
 Gently tug on control wires to ensure a tight connection or use a screwdriver to gently verify
torque on the connection
 Tighten all the connections as required.
Electrical Checks to be followed before Commissioning and energizing RMU.

Checks of Cable Compartment before Final Commissioning:

 Check that all testing equipment, leads, tools, bridges and shorts have been removed from HV
cable enclosure.
 Check that all VCBs are open and all earth switches are closed.
 Check that all cables still dead and isolated before reconnecting cables to RMU.
 Check that all cable boots are bagged and secured where applicable.
 Check boots have no foreign material, dead end receptacle etc.
 Check that dead end receptacle have been fitted, greased and tight.
 Check that venting rod has been removed.
 Check that all the HV cable terminations are secure and that the correct bailing assemblies are
used.
 Check that all the HV cable terminations are tightened to the manufactures required standard.
 Check that the drain wires are fitted to all HV elbow connectors and are connected to the cable
screen.
 Check that the HV cable screens are all solidly and separately connected and bolted to the HV
earth bar.
 Check that there is a 25 mm clearance between the cable screens and the cable support
brackets.
 Check that phase indication wires are connected to bushings.
 Check that HV cable plug earth drain wires have been connected and earthed.
 Check that all cable screens have been connected to earth.
 Check that all CT’s have been installed correctly and cables connected correctly.
 Check that all secondary wiring in HV cable enclosure have been terminated and secured.
 Check that all earthing has been correctly connected.
 Check that any foreign materials have been removed from the cable enclosure.
 Secure HV cable enclosure covers.
 RTU (if installed) – Check all CT’s, VT’s, Gas, Door switch cables are correctly connected.
 Check that no HV cables are exposed. Backfill if necessary

General Wiring Checks for Switchgear

 Wire inserted in the Panel will be cross-checked for existing circuit number done and final
ferruling shall be done as approved drawing.
 Wire in Panel shall be used cable tie and dress with bunching of the phase-neutral and earth
and lugged to the respective MCBs and Bus bar as per approved drawing.
 Bunching shall be done as per phase separation respectively R, Y and B.

Moving Parts and Interlock Checks for Switchgear

 Confirm the correct operation and sequencing of electrical and mechanical interlock systems.
Attempt closure on locked-open devices and attempt to open locked-closed devices.

Lubrication of Switchgear and Switchboards

 Check for appropriate lubrication on moving current-carrying parts and moving/sliding
surfaces to keep everything operating smoothly. This includes hinges, locks, and latches.
Insulators and Barrier Checks for Switchgear
 Tracking is an electrical discharge phenomenon caused by electrical stress on insulation. This
stress can occur phase-to-phase or phase-to-ground. Although tracking can occur internally in
certain insulating materials, these materials as a rule are not used in medium- or high-voltage
switchgear insulation. Tracking, when it occurs in switchgear assemblies, normally is found on
insulation surfaces.
 Electrical insulators should be inspected for evidence of physical damage or contaminated
surfaces. Damage caused by electrical distress is normally evident on the surface of insulating
members in the form of corona erosion or markings or tracking paths.
 Inspect barrier and shutter assemblies for proper installation and operation. All active
components should be exercised, mechanical indicating devices should be inspected for correct
operation.

Moisture and Corona Inspections for Switchgear and Switchboards

 If corona occurs in switchgear assemblies, it is usually localized in thin air gaps that exist
between a high-voltage bus bar and its adjacent insulation or between two adjacent insulating
members. Corona might also form around bolt heads or other sharp projections that are not
properly insulated or shielded. Corona in low-voltage switchgear is practically non-existent.
 Inspect for evidence of moisture or corona when performing maintenance inspections. On
outdoor assemblies, roof or wall seams should be checked for evidence of leakage, and any
leaking seams should be sealed with weather proof caulk

Testing & Commissioning Methodology

 Below is the list of required tools for ring main unit testing that should be arranged before
starting the testing and commissioning:
 Primary Injection kit
 Contact Resistance kit
 High Voltage test kit
 5.0 KV Megger
 Timer
 Multi meters
 3-Ph Relay Tester (Secondary injection Kit)

Testing of RMU Panel : When Installation is completed, carryout testing and commissioning as per
the procedure below.

 Bus bar Testing

 Measurement of Contact Resistance on Bus bars
Inject successively a DC current of 100A for each phase at level of connections and note down
the Low resistance value which shall be in Micro ohms. Or use an apparatus with direct
reading (micro ohmmeter), injection 100A DC current.

 Insulation Resistance Measurement

When the breaker in closed position measure the insulation resistance Phase to earth with 5.0
KV DC. Then open the breaker and measure the insulation resistance between pole to pole.
The above, will be carried out for all the phases.
 Primary / Secondary Insulation Resistance Measurement

 Remove CT earth connection on secondary terminals Measure insulation resistance between

core & ground Equipment to be used: 5 KV Insulation testers.
 CT primary is insulation resistance measured by applying 5KV DC. When meggering each phase
other phases will be kept earthed.
 Secondary circuit Insulation resistance measured by applying 500V DC to each core with
respect to earth and core to core .
 Insulation between Primary and Secondary winding

 Circuit Breaker Testing

 Insulation Resistance Measurement
When the breaker in closed position measure the insulation resistance Phase to earth with 5.0
KV DC. Then open the breaker and measure the insulation resistance between pole to pole. The
above, will be carried out for all the phases.
 Contact Resistance Test
The breaker will be in closed position before starting the test.
Inject successively a DC current of 100 A for each phase top and bottom, and measure the milli
voltage drop by the Multimeter. Otherwise connect the contact resistance kit and measure the
resistance values in micro ohms directly.

 EARTH FAULT INDICATOR:

Current injected check earth fault indicator 25 A

Operated Check earth fault indicator flag reset by depressing the reset Plunger.

 D.C. Battery (UPS)

Condition of battery system

Voltage of battery cell measured

 Primary injection
 Current is passed through the primary conductors and measured on the test set ammeter
A1 shown in below figure. The secondary current is measured on the ammeter A2 at
terminal board or relay display, and the ratio of the value on A1 to that on A2 should closely
approximate to the ratio marked on the current transformer nameplate.
 Ensure that protective device is powered up (RELAY), And the protection function
(50,50N,51,51N) Under Test is enabled.
 Keep increasing the current until the circuit breaker trips.
 Polarity of CTs and Relay will also be confirmed in this test
 CT Ratio Check
 Current is passed through the primary conductors and measured on the test set ammeter,
A1 in Figure. The secondary current is measured on the ammeter A2 or relay display, and
the ratio of the value on A1 to that on A2 should closely approximate to the ratio marked on
the current transformer nameplate

 Tripping and Alarm Annunciation Tests

 CB trip coils and/or alarm circuits may have been isolated during transit. In such cases, it is
essential that all of the tripping and alarm circuits are checked. This is done by closing the
protection relay contacts manually and checking that
1) The correct circuit breakers are tripped x the alarm circuits are energized
2) The correct flag indications are given
3) There is no mal operation of other apparatus that may be connected to the same
master trip relay or circuit breaker.

 Secondary Injection Tests

Overcurrent/Earth fault Relay / Transformer Protection

Check the Overcurrent /Earth fault settings and verify as per approved settings.
Check that the necessary protections are enabled as per the relay coordination study
Check all transformer protection are working and all logics of Transformer are signalised to
master trip

Testing the logic of protection schemes

 Checking of the scheme logic specification and diagrams to ensure that the objectives of
the logic are achieved
 Testing of the logic to ensure that the functionality of the scheme is proven
 Testing of the logic, as required, to ensure that no output occurs for the relevant input
signal combinations.
 Metering
 Check all the current meters are working properly
 Check all the Voltage meters are working properly
 Check all the Power Meters are working Properly.

RMU/HT Commissioning Step

The following sequence will be carried out for testing.

 Check the Earthing Busbar tightness check
 Record corresponding contact resistance
 Check the contact resistance for the bus bar / breaker as per the procedure mentioned
below
 Check the Breaker timing test.
 Connect the auxiliary supply to the respective cubicles as per the schematic drawing
 Check the ratio/ circuit for the current transformer by primary injection.
 Check the secondary injection for relays.
 Check the functional test for RMU.
 Check the remote signals up to our Panel terminal blocks only.
 Check the High voltage test for the switchboard
 Insulation resistance test of CT and switchgear.

COMMISSIONING AND ENERGISATION of RMU/HT Panel

 The commissioning officer must ensure that all checks are completed and the test
results comply with the minimum standards.
 Ensure that the high voltage cable testing schedule is available and that the results are
acceptable.
 Ensure that the earth system test result is available and that the results are acceptable.
 The switching operator must ensure that the switchgear labels match the GIS diagrams.
 Ensure that all equipment is in its final circuit condition as per the switching program.
 Ensure that all equipment is locked, numbered and labelled correctly, and secure from
unauthorized entry observe line voltages of all 3 Phase and in meters.
 After safe charging of incomer panel, charging of Outgoing Panels is to be followed as
per transformer commissioning methodology.
 Ensure the work area is left tidy with no hazards to the public.
 Hand over responsibility to the operating authority Commissioning and as a document
required for the Handover Certificate.
 LT PANEL
Inspection of LT Panel

General Check of LT / Auxiliary Panel

 Check the reference of delivered material against approved submittal and purchase order.
 Check The Material according to its Type, Size, Make
 Check for Damage/Defects to the body or fuses
 Check Quality For Paint Work
 Check Tightness Of All Bolted Connections (by Torque wrench method)
 Check That All Grounding Are Securely Connected
 Check the interlock system
 Ensure that the earth system is completed as per design drawings
 Check that the switchgear is numbered and labelled correctly.
 Inspect labels, markings, safety signs and safety devices.
 Check the connections for conformity with the reference drawings and their tightness.
 Number terminals, cables and component parts to correspond with manufacturer have certified
drawings.
 Ensure that vents are clear and filters are in place. Screens covering ventilation openings should
be in place to prevent entry of rodents or small animals.
 Check the outer appearance (absence of any traces of shocks, peeling paint) -carry out any
touch-ups if needed.
 Check the alignment of face plate and operation of the interlocks.
 Check the conditions of all Metering equipment’s and general wiring
 Check Continuity of Main, Auxiliary, Earthing and Neutral Busbar with respect to incomer and
outgoing Circuits.
 Check that it is not possible to come into contact with energized equipment when working on
the system.
 If there are any Correction or modification than Check All internal connections/modification will
be carried out by the Manufacturer.
 Check the main bus bar and auxiliary circuits (control, monitoring, alarm, and fault) for
continuity.
 All breakers (incoming/outgoing) shall be in “OFF” position and to be locked to prevent
mishandling
 Check that the panel hinged doors are connected to the frame by earthing braids.
 In case of any damages observed during inspection, the concern report will be issued and
Material shall be returned to the supplier for replacement.
 Fully tight all Bolted electrical connections of Electrical Switch gear of Panel.
 Check for Loose bolted electrical connections. It can lead to higher energy consumption and
eventual equipment failure if not properly addressed.
 Check for Loose control, Power wires can lead to spark, over heat which turns in to catastrophic
failure.
 Check that all wiring connections are tight and that wiring is secure to prevent damage during
routine operation of moving parts, especially when removing draw-out circuit breakers or
opening and closing cubicle doors.
 Gently tug on control wires to ensure a tight connection or use a screwdriver to gently verify
torque on the connection
 Tighten all the connections as required.

Checking of Air Circuit Breaker

 Cleaning of breaker with CRC-226 if foreign particles found.
  Check condition of arcing contact and gap between fixed and moving arcing contacts shall be
checked.
 Checking the reset mechanism, tripping of breaker through push button
 Checking tripping of ACB through protection release
 Tripping of ACB manually through volt metric release.
 Checking and adjust freeness of DN and volt metric release trip rod
 Checking presence and proper tightening of hardware.
 Checking presence of all circlips
 Checking condition of ACB wiring and replace if required
 Checking proper closing of all poles together
 Checking working of anti pumping device in case of EDO ACB
 Checking alignment of SIC and it’s operation
 Checking scrapping earth alignment
 Checking condition of arc chutes
 Checking U/V release pick up and drop off
 Checking ACB tripping through shunt release
 Checking motor operation
 Checking closing coil operation
 Checking continuity and proper changeover of aux contact block
 Checking of release by secondary injection for O/L, S/C, E/F
 Setting of release as per the load
 Checking the healthiness of CTs
 Checking the spare parts, accessories.

Checking of Moulded Case Circuit Breaker

 Inspection of MCCB Enclosure

 Checking of Wire Connectors/Connections
 Checking of Mechanical Operation through switch
 Checking of Breaker Assembly
 Checking of condition of Auxiliary Switch
 Checking of Alarm Switch
 Checking continuity
 Checking proper closing of all poles together
 Checking of Shunt Trip Release
 Checking of Under-Voltage Trip Release

General Wiring Checks for LT/Auxiliary Panel

 Wire inserted in the Panel will be cross-checked for existing circuit number done and final
ferruling shall be done as approved drawing.
 Wire in Panel shall be used cable tie and dress with bunching of the phase-neutral and earth
and lugged to the respective MCBs and Bus bar as per approved drawing.
 Bunching shall be done as per phase separation respectively R, Y and B.

Moving Parts and Interlock Checks for LT/Auxiliary Panel

 Confirm the correct operation and sequencing of electrical and mechanical interlock systems.
Attempt closure on locked-open devices and attempt to open locked-closed devices.
Lubrication of LT/Auxiliary Panel and Switchboards

 Check for appropriate lubrication on moving current-carrying parts and moving/sliding

surfaces to keep everything operating smoothly. This includes hinges, locks, and latches.

Insulators and Barrier Checks for Switchgear

 Tracking is an electrical discharge phenomenon caused by electrical stress on insulation. This

stress can occur phase-to-phase or phase-to-ground. Although tracking can occur internally in
certain insulating materials, these materials as a rule are not used in medium- or high-voltage
switchgear insulation. Tracking, when it occurs in switchgear assemblies, normally is found on
insulation surfaces.
 Electrical insulators should be inspected for evidence of physical damage or contaminated
surfaces. Damage caused by electrical distress is normally evident on the surface of insulating
members in the form of corona erosion or markings or tracking paths.
 Inspect barrier and shutter assemblies for proper installation and operation. All active
components should be exercised, mechanical indicating devices should be inspected for correct
operation.

Moisture and Corona Inspections for Switchgear and Switchboards

 If corona occurs in switchgear assemblies, it is usually localized in thin air gaps that exist
between a high-voltage bus bar and its adjacent insulation or between two adjacent insulating
members. Corona might also form around bolt heads or other sharp projections that are not
properly insulated or shielded. Corona in low-voltage switchgear is practically non-existent.
 Inspect for evidence of moisture or corona when performing maintenance inspections. On
outdoor assemblies, roof or wall seams should be checked for evidence of leakage, and any
leaking seams should be sealed with weather proof caulk

Metering

 Check all the current meters are working properly

 Check all the Voltage meters are working properly
 Check all the Power Meters are working properly.

Cleaning

 Dirt accumulated, can cause the components of the ACB/MCCB to deteriorate. After installation
of panels Use a vacuum cleaner to get rid of the dirt. With the dirt removed, even your visual
inspection becomes much easier

Testing of LT

Before Testing Procedure Certain Testing Equipment has to be available with the Testing Engineer

 Contact Resistance Measurement Kit

 HI POT / HV Test Kit
 1KV Insulation Tester
 Electronic Trip Unit
 Multi meters
  Primary Injection kit

Testing of ACB

 Insulation resistance test

This test should be performed using a Megger phase-to-phase and phase-to-ground with the
breaker in the closed position, as well as across the open contacts for each phase. Use the
manufacturers recommended test voltage and acceptance values for this test.
 Control Wiring
All circuit breaker control wiring should be insulation tested as it can easily be cut on sharp
edges when moving the breaker in and out of its cell. It only takes a single wire shorted inside of
the circuit breaker to prevent it from effectively clearing a fault. This could result in failure of
the trip coil, charging circuit, or even the protective relay.
Perform this test by connecting all points of the secondary disconnect pins together and
measure insulation resistance from the wire to the circuit breaker frame or chassis. Use caution
when conducting this test, don't apply high voltage to the spring charging motor or solid-state
devices; isolate these items prior to insulation resistance testing.
 Dielectric withstand voltage test
Dielectric withstand is basically a hipot test. This test picks up where insulation resistance left
off; it's used to detect tracking, deterioration, and moisture in the insulation system at a much
higher voltage.
The use of an AC high potential test set is recommended when testing medium-voltage circuit
breakers. Always use test voltages specified by the manufacturer. When recommendations are
not available, or not provided, IEEE Specifications can be used.
Dielectric withstand testing is performed from the line side of each phase, with the breaker
open, all other phases tied together and connected to ground.
Test current should be equal to the rating of the circuit breaker or 100 amperes. Using a test
current less than 100A is acceptable measured resistance values should be within 50% of each
adjacent phase, and comparable to similar breakers as stated in Testing Specifications IEEE. The
resistance should not exceed the factory test levels by more than 200% as stated in IEEE C37.09.

 Relay Testing for ACB's (ETU Tests)

In addition to these three basic tests, functional testing of the trip and close circuit should be
performed via the manual controls. It's even more important that the breaker be tripped via the
protective relay to ensure that the relay and breaker are working together.
The protective relays should also be tested individually for functionality. In typical industrial
power systems, over-current protection is the principal, and sometimes only, function provided
by the relay; however, if there are other protective functions enabled, they should be tested as
well.
Don't forget to affix the appropriate field testing label for indication of the Testing date and the
overall condition of the devices that have been tested and maintained.
  While protection system testing and calibrating , below items are performed.
 Long Time Protection Trip
 Short Time Protection Trip
 Instantaneous Protection Trip
 UVT pick up and Release Trip

Setting is to be applied as per the relay co-ordination study given by CZ.

Tests are carried out for LV Panel Phase seq. / Ct / Meter Confirmation
Primary current injection

Testing of MCCB

 Testing Insulation Resistance

This test is done to ensure that you get reliable protection. It requires you to disconnect the
MCCB so that you can test the insulation across the load terminals, supply terminals and
between phases. If the insulation resistance is found to be lower than the manufacturers’
recommended value, then the protection is not adequate.
 Testing Contact Resistance
Usually, this is a rather low value because the MCCB needs to allow current to pass through
even when it has a low voltage. You will need to test the resistance of electrical contact and
then compare your findings with the manufacturer’s recommendations.
 The Tripping Test
You will need to simulate a fault or overcurrent and then observe how the MCCB responds. You
want to carry out this test last since the MCCB will heat up due to the high current. It is a two-
part test which is conducted in the following sequence:
 Thermal Protection
This is where you use an over-current about 300 percentage above the rated value. Ideally, the
breaker should trip correctly. If it doesn’t then it is failing in thermal protection.
 Magnetic Protection
Here you would want to simulate a fault by sending pulses of current that are very high. The
pulses need to be very short since a fault can be very dangerous. Magnetic protection tends to
be instant and these can be handled well by the application.

COMMISSIONING AND ENERGISATION of LT/Auxiliary Panel

 The commissioning officer must ensure that all checks are completed and the test results
comply with the minimum standards.
 Ensure that the LV cable testing schedule is available and that the results are acceptable.
 Ensure that the earth system test result is available and that the results are acceptable.
 The switching operator must ensure that the switchgear labels match the GIS diagrams.
  Ensure that all equipment is in its final circuit condition as per the switching program.
 Ensure that all equipment is locked, numbered and labelled correctly, and secure from
unauthorized entry. Observe line voltages of all 3 Phase and in meters.
 After safe charging of incomer panel, charging of Outgoing Panels is to be section wise for Each
category of LOAD
 Ensure the work area is left tidy with no hazards to the public.
 Hand over responsibility to the operating authority Commissioning and as a document required
for the Handover Certificate.

Cables
HANDLING

Cables are generally received wound on wooden drums, both the ends of the cable being easily
accessible for inspection and testing. However, short lengths may be transported without drums.

In case of PVC and XLPE both the ends of cables should be protected from moisture by means of cables
sealed plastic caps should be used.

The cable drums or coils must not be dropped or thrown from trucks during unloading operations. A
ramp or crane may be used for unloading cable drums. If neither of these is available, a temporary ramp
with inclination 1 : 3 to 1 : 4 approximately should be constructed.

The cable drum should then be rolled over the ramp by means of ropes and winches. Additionally a sand
bed at the foot of the ramp may be made to brake the rolling of cable drum.

All drums or Cables should be stored in such a manner as to leave sufficient space between them for air
circulation. & not to be stored in Water Clogged Places.

GUIDELINES FOR CABLE LAYING AND INSTALLATION

Selection of the Route

The selection of the route should first be decided keeping in view the immediate and ultimate use of the
cable as an integrated part of the installation.

If possible, Plans for future Expansion should be considered while laying the cables

The route should be, as far as possible away from parallel running water pipes and
telephone/telecommunication cables.

Suitable locations for cable joints and end terminations should be selected as required.

Minimum Permissible Bending Radius of the cable should not bend to a sharp radius. Minimum
recommended bending radius are given in Table(see Fig ). Wherever possible, larger bending radius
should be used.
Clearances:

The desired minimum clearances are as follows:

Power cable to power cable Clearance: Clearance not necessary; however, larger the clearance, better
would be current carrying capacity.

Power cable to control cables: 0.2 m

Power cable to communication cable: 0.3 m
Power cable to gas/water main: 0.3 m

Although Inductive influence on sensitive control cable on account of nearby power cables should be
checked.

Laying Direct in Ground

This method involves digging a trench in the ground and laying cable(s) on a bedding of minimum 100
mm riddled soil or sand at the bottom of the trench, and covering it with additional riddled soil or sand
of minimum 100 mm and protecting it by means of tiles, bricks or slabs.

Depth - The desired minimum depth of laying from ground surface to the top of cable is 1 meter

Drawing the Cables into Ducts Pipes

When drawing the cables into ducts, lack of space in the drawing pits usually restricts the distance from
the drawn duct mouth and it is essential that the direction of curvature of the cables is not reversed as
it enters the duct.

On long run ducts, it is desirable to apply lubrication to the lead or serving/outer sheath as it enters the
duct. Petroleum jelly or graphite powder or a combination of both is effective for this purpose and
through lubrication will reduce the pulling tension by about 40 percent. Alternatively, graphite finish
over the serving/outer sheath of the cables would equally serve the purpose. The duct" having bell
mouth ends should be laid at all man-hole positions in the cable unless otherwise protected to avoid
sharp edges.

While fixing the cables in ducts, stockings or pulling eyes may be used. Stockings are slipped over the
cable surface while the pulling eyes are connected to the conductors. Pulling is carried out with manual
labour by means of winches or other mechanical means when the cable to be pulled is fairly long
Laying on Racks in Air (Cable Tray)

Racks may be ladder or perforated type and may be either fabricated at the site or pre-fabricated.
Considerable economy can be achieved using standard factory made racks. The necessary , size of the
racks and associated structure has to be worked out taking into consideration the cable grouping and
permissible bending radius.

The space provided for cable racks has to be sufficient. They are generally fixed to the wall or supported
by free standing columns or structures enabling easy installation or replacement of cables.

The vertical distance between the two racks should be minimum 0·3 m and the clearance between the
first cable and the wall (if racks are mounted on wall) should be 25 mm. The width of the rack should
not exceed 0·75 m in order to facilitate installation of cables.

Ungalvanized steel work of cable racking/trays should be painted with a coat of primer and thereafter
finished with suitable anti-corrosive paint.

Only single-core cables laid on horizontal racks need be clamped at suitable intervals. Multi-core cables
need not be clamped.

The distance between the vertical clamps should not be more than 2 m

Cables Suspended from Catenary Wire - In certain section it may be necessary to install a cable across
an area, suspended from a catenary wire by means of steel/aluminium/leather suspenders. The
suspenders are hung from catenary wire by means of GJ dropper wires. The catenary wires should be of
galvanized steel of adequate strength and of stranded construction. The two ends of the catenary wires
should be connected to rigid supports by means of GJ turnbuckle. The rigid supports may be of steel
poles/structure of adequate strength. It is advisable that cable suspended from a catenary wire is
provided with sun shield to protect the same from direct heating by sun's rays.

Laying of Cables on Racks inside a Tunnel.

The cables are in unventilated tunnel. the heat generated in the cables is dissipated only through the
walls of the tunnel. Consequently there is an increase in the temperature of the cables installed in the
tunnel and accordingly a proper derating has to be applied to the current carrying capacity of the cables
installed in the tunnel.

In the case of 'Passable' cable tunnel, the head room should not be less than 2 m and width sufficient to
leave a free passage of at least 600 to 800 mm either from one side or in the middle. Due consideration
should be given for adequate ventilation, lighting and drainage.

RCC TRENCHING With Cover

The Cables are Directly Laid in to RCC trench. After Laying activity Trenches are to be closed down with
covers. Where necessary clearance of the power and control cable are to be maintained

EARTHING AND BONDING

The metal sheath, metal screen (if any) and armour of any cable should be efficiently earthed at both
ends.
All metal pipes or conduits in which the cables have been installed should be efficiently bonded and
earthed.
Where cables not having metallic sheath are used, embedding additional earth electrodes and
connecting the same with steel armour of cable becomes necessary,

Typical end termination for II kV grade Cable

For XLPE cables above 3·3 kV and up to 11 kV ( screened ), self-amalgamating tapes ( both insulating and
semiconducting) are used for providing stress-relieving mechanism in the joints. Preformed stress-
relieving cloths or tubes are also used for stress relieving mechanism in place of self-amalgamating
tapes.

REINSTATEMENT of Cables

After laying the cables, it should be checked again to see that the all cable ends are undamaged and
sealed.

If trench is partially filled with water, cable ends should be kept clear off water as far as possible. If cable
has to be cut, both the cable ends should be resealed immediately" Lead cap for paper cable and plastic
cap for PVC cable should be used. As a temporary measure, ends can be sealed by inserting them in an
empty tin which is filled with hot bitumen based compound.

The cable ends should overlap at the joint box point by at least half the length of latter. The ends may
be looped to provide extra lengths in case of extruded dielectric cables. Each cable length should be
aligned immediately after it is laid starting from one end.

If the joints are not to be made immediately after laying the cable, the cable ends should be covered.
The position of the cable joint should be marked with markers.

The trench at the duct mouth at road or railway crossing should be deepened to prevent the stone or
the gravel from being drawn into duct and clogging it.

Before the trench is filled in, all joints and cable positions should be carefully plotted by draughtsman.
The requisite protective covering should then be provided. the excavated soil replaced after removing
large stones, and well rammed in successive layers of not more than 0'3 m in depth. Where necessary,
the trenches should be watered to improve consolidation. It is advisable to leave a crown of earth not
less than 50 mm in the centre and tapering towards the sides of the trench to allow.

CABLE INSTALLATION PLAN

On completion of laying, terminating and jointing of the cables, a plan should be prepared, which should
contain the following details of the installation.
a) Type of cables, cross-section area, rated voltage. Details of construction, cable number and drum
number;
b) Year and month of laying;
c) Actual length between joint-to-joint or ends;
d) Location of cables and joints in relation to certain fixed reference points, for example, buildings,
hydrant, boundary stones, etc;
e) Name of the: jointer who carried the jointing work:
f) Date of making joint; and
g) Results of original electrical measurements and testing on cable installation.
All subsequent changes in the cable plan should also be entered

Testing and Electrical Measurement of Cable after Installation

Insulation Resistance Test on Newly Installed Cables before Jointing

Insulation resistance is measured by a suitable bridge. the insulation resistance of each core is
measured against all the other cores and armour/metal sheath connected to earth. With screened
construction the insulation resistance of each core is measured against all the other cores and the metal
screen connected to earth.

The Test should be for 60 sec. Reading has to be taken in Log book for all Combinations
RY-YB-BR
RE-YE-BE

High Voltage Test

Cables after jointing and terminating are subjected to DC high voltage test.
The recommended values of test voltages are given in Below Table .
The leakage current shall be measure for all Phases.

Method for Bus Duct Installation & Testing

Handling, Storage, and Transportation
 Upon receiving the material, it must be inspected and ensured that they are free from any
manufacturer defects. The material shall be handled with care and shall be stored at the
 designated area as per the manufacturer’s recommendation prior to installation. Any
discrepancies, damages, etc., shall be notified and reported for further action.
 The busbar is protected from minor water ingress by means of an overall outer polythene wrap
and individual polythene stretch wrap around the ends of each bus bar.
 The material will be delivered at the site in undamaged condition in the manufacturer’s
packaging with identifying labels intact and legible.
 Each shipment must be blocked and securely fastened to avoid damages during transportation.
 Unloading at the site must be controlled by site management following the manufacturer’s
instructions. Manufacturer recommendations shall be followed strictly while handling the
material during installation activity.
 Lay down area must be arranged for offloading the material prior to transport to the site.
 Ensure that the storage area is at a minimum height of 1 ft from the ground level.
 Ensure that the proposed storage area for the material is clean.
 A separate area in the storage zone must be marked for different materials.
 Ensure that the material is stored in a shaded area to protect it from exposure to direct sunlight.
 If the busbar is not to be installed immediately upon delivery, it should be stored in a clean and
dry area to prevent condensation. Do not allow the busbar to contact with corrosive fumes,
liquids, and other foreign matters.

Tools and Equipment

The following are the types of Tools identified for works:
 Fork Lift for transporting Busbar
 Chain Block pulley (suitable capacity)
 Portable Hand Tool
 Measuring Tape
 Marker Tape
 Spirit Level (1.5m to 2m long)
 Drilling Machine
 Torque Wrench tools
 Level Threads
 Hammer
 Multimeter
 Standard Electrical tool kits
 1000V Megger
 Simple Electrical Tools (plier, screwdriver set and etc.)
 Ladder

Methodology-Bus Duct Installation

 Preparation for Installation

 The start of the busbars installation shall be done in accordance with approved shop drawings
and properly coordinated with site engineers for the exact locations and levels. The. mark on-
site to be carried out prior to commencement of installation works.
 Prior to the commencement of the works, inspect the areas for safe access and confirm the
same are in suitable condition for the works.
 All materials and documentation relevant to this particular works shall be checked by the
project Engineer to confirm adequacy and compliance with the requirements prior to the
commencement of works.
 Only approved materials shall be used for the site works. Material inspection approval shall be
checked and verified by the Project Engineer.
  The Project Engineer or Site Engineer should check the approved isometric drawings of busbar
layout and ensure that all sections of the busbars are received at the site.
 During shifting to the installation location, lift the busbar and its associated fittings using proper
lifting equipment or manually with an adequate number of people. Never drag the busbar
across the ground, handle with care to avoid damage to internal components and enclosure.
 Prior to the start of the installation works, the team shall coordinate with the builder’s work
activities at the site to ensure the proper work installation.
 Prior to installation, ensure that approved shop drawings for construction details of bus duct
arrangement and bus duct routing are available as approved by the supervision . This drawing
should be followed carefully to ensure a proper busbar system.
 All involved personals will wear appropriate protection at all times during the entire period of
unloading/ shifting.
 Hazard analysis and risk assessment shall be explained to all personnel involved in the
installation of the busbar and its accessories.
 After satisfactory completion of the above steps, works shall commence in the respective areas.
 Works shall be carried out at site under strict supervision and guidance of the
supervisors/engineers.
 Installation/Work Sequence
 Installation of busbar starts from the transformer to MV Panel. During the installation, a chain
block (1-2 tons) will be used to lift the busbar and its components to their proper position as per
the approved drawing. During the installation process workers involved wears appropriate
safety protections.
 Distribute pieces of the busbar and its associated fittings to each level as per the approved
drawing details of bus duct arrangements. In shifting the materials to each level tower
crane/forklift will be used or manually with an adequate number of people. All involved
personnel must wear appropriate personnel protection during the entire period.
 Install horizontal busbars & vertical busbar riser including its supports in accordance with the
approved specification, manufacturer’s recommendation & approved shop drawing.
 Horizontal Mounting Support
 Use approved channel/hanger flat & down the rod as per manufacturer’s recommendation.
 Busbars are installed by tightening the “one bolt joint”. Belleville spring washers on both ends
of the bolt retain the original contact pressure, ensuring a more secure, reliable, and
maintenance-free joint.
 Once the busbar is aligned and jointed properly, the bolt is tightened to 83Nm (60 lb-ft) using
the torque spanner.
 During the installation maintain good alignment of the drop rods along the busbar run; do not
support the busbar at the joints. After the busbar is secured in the hangers, adjust the hangers
on the rod for the correct elevation.
 Use min 10mm galvanized steel bolt to fix busbar to supports with required nut and washer.
 The joint shall be done as per the manufacturer’s recommendations; this is to avoid any ingress
of moisture into the bus duct system.
 Prior to joining, both sections of the bus duct to be joined undergo continuity & insulation
resistance tests and record the results in the approved format. Joints shall be made by simply
sliding together the bus duct unit, and tightening the clamping bolts progressively to the specific
torque (83Nm). Ensure that all joint contact surfaces are free of contamination and dirt.
 Install expansion joint wherever required in accordance with contract documents, approved
shop drawing & manufacturer’s recommendations as well as on every building expansion joint.
 After the erection, use vinyl or corrugated cardboard or polythene sheets to cover the power
busbar system, protection for concrete, plaster, and water damage, etc.

Transformer Terminal Connection

  Make sure the rigid busbar is connected properly. On the top of the LV cable box, the
transformer connection unit is to be installed, and then flexible are used to connect the
connection unit to transformer terminals.
 Joints shall be made by simply sliding together the unit, and tightening the clamping bolts
progressively to the specific torque (83Nm). Ensure that all joint contact surfaces are free of
contamination and dirt.
 Any missing tools or equipment shall be provided for perfect installation.
 Upon completion of installation manufacturers or dealers, engineers will inspect and certify the
installation.
 Ensure a danger notice is fitted to all access panels where a voltage exceeding 200V and the
power busbar system is protected until the building is clean, and the system is ready to be
energized.
 When installing a busbar section with a fire barrier ensure that the fire barrier protrudes from
both sides of the wall. Final sealing between fire barrier and wall to be completed.
 Continuity testing of Bus bar
 Prior to installation of power busbar system and before electrical circuitry has been energized,
demonstrate product capability and compliance with requirements.
 Perform continuity test to both sections of bus duct to be joined and to be recorded to ensure
proper connections. If satisfactory readings cannot be achieved, remove and replace mal-
functioning busbars with new units and retest.
 Measure resistance between phases, and earth using megger. (The mega ohm readings should
not be less than the value recommended by the manufacturer.)
 Upon installation, measure the resistance of each major branch. In case of low readings, re-
tighten all joint bolts in the busbar section being tested using a torque wrench. If satisfactory
readings cannot be achieved, remove and replace mal-functioning busbars with new sets and
retest.
Inspection and Test plan
 The engineer should verify that the supervisor/foreman with construction responsibilities for
installation is familiar with this method statement and is issued with copies of the inspection
checklists and test plans.
 The engineer should satisfy the procedures provided by MFGr inspections to ensure the as-
installed condition of the Busbars installation meets the specified engineering requirements and
approved drawings.
 As part of the assessment, the QA/QC Inspection Procedures must ensure quantitative or
qualitative acceptance criteria for determining the prescribed activities have been accomplished
satisfactorily.
 Inspection personnel in coordination with the Site Engineer and Supervisor should verify that
the quality of the related Busbars installation activities is within the prescribed criteria.
 The Site Engineer should verify any as-built record of Busbars installation. Confirm that the
information meets the project requirements.
 Project Engineer and Site Supervisor will monitor that all components are installed as per
contract specifications and approved submittals.
 Readable stamped approved drawing to be available during installation and inspection.
 All the equipment engaged for testing shall have a valid calibration and a certificate should be
furnished
Grounding and Earthing

APPLICABLE CODES, STANDARDS AND SPECIFICATIONS

The supply, installation and testing of earthing material & accessories shall comply with all currently
applicable statutes and regulations where the equipment will be installed. Nothing in this specification
shall be construed to relieve the BIDDER of his responsibility. Where no standards are available, the
supply items shall be of good quality and workmanship and backed by test results..

Equipment shall confirm to the latest applicable standards and codes of practice as mentioned in this
specification. In case of conflict between the standards, stringent specifications out of these standards
shall govern. Whereas in case of conflict between the standards and this specification; requirements of
this specification shall govern. Other National standards are acceptable, if they are established to be
equivalent to or superior to the listed standards.

The equipment / installation work shall also confirm to the currently applicable standards and codes of
practice, standards and specifications as listed below:

IS:613 Earthing rods for electrical purposes

IS:1897 Earthing strip for electrical purposes
IS:3043 Code of practice for earthing Indian Electricity rules The Electricity (Supply) Act 4.

Methodologies shall be followed for Earthing

i). Schematic diagram for earthing is provided by CZ.

a). The location of the earth pits will be identified by the Engineer in-charge at the site.

b). The complete SITC of earthing system should conform to drawing provided by CZ.

c). Earth pit of size of 1 meter diameter & 3 meter depth shall be excavated in all type of soil at site till
the wet soil. After 3 meter depth, the size of excavation shall be 900X300X900 mm for burying copper
plate.

d). A tinned copper plate of 600X600X3mm will be buried vertically in depth as described below.

e). The copper plate shall be connected to copper earth strip of 25X3 mm at minimum two points and
joints shall be protected by heavy coat of bitumen.

f). At bottom, 150 mm layer of salt and charcoal(wooden) powder shall be filled then copper plate shall
be installed.

g). Minimum 120kg each of charcoal (wooden) powder and salt shall be used.

h). Supply and installation of Φ50 mm, 2000 mm long, Class-C, GI pipes with funnel for watering
including supply of all material such as charcoal, salt etc, required for earthing system are also included
in scope of bidder.

i)The quantity of earth strip to be laid at each location will be as per the direction of Engineer in-charge.

J) Welding should be free from defects; the joint is to be properly cleaned.

K) Bolting of earth strips to be done at end of connecting earth strip to earth pit and also at the other
end where earth strips are connected to equipment’s/structures etc.
L) Deployment of men, transportation of man & machinery, consumables, welding equipment, drilling
machine to various locations necessary for carrying out the Earthing grid arrangment comes under
bidder’s purview.

M) The bidder is responsible for any damage caused while carrying out earth pit jobs.

N) Drains, pipes, electrical cables, telephone cables, and similar services encountered in the course of
the works shall be guarded from injury by the bidder at his own cost, so that they may continue in full
and uninterrupted to the satisfaction of the /CZs thereof.

O) Should any damage be done by the bidder to any mains, pipes cables or lines (whether above or
below ground etc. whether or not shown on the drawings the bidder must make at his cost good the
damage without delay to the satisfaction of the engineer-in-charge.

P). Earthing strip shall be continuous for entire length, joints shall be avoided as far as possible. Earthing
strip shall not have any cut-outs or switches or links.

Two separate and distinct connections shall be taken out from plate earthing.

Q). Interconnection of earth and main branch of earth should be made in such a way that reliable and
good electrical contact is established.

R). The path of earthing strip should be minimum as possible, be out of reach of any person. For earth
resistance please refer to IS-3043:1966-10 page –32

S). All material, fitting etc. used for earthing and earthing pit should be of IS specified make and
standards

T). Anti-corrosive measures: Earth strip should be protected against mechanical damages and corrosion.
Fittings should be resistant to the corrosive agencies or be otherwise suitably protected. Joints and
bonds may be protected with bitumen or embedded in plastic compound according to the local
conditions.

U). Bidder shall carry out the work, which is required for completion of work and not mentioned in the
specification such brazing, chipping and breaking of masonry work etc.

V) Warrantee/Guarantee: The complete SITC of the earthing system shall be guaranteed in all respects
for satisfactory performance & measurement of Earth Resistance (below 1 ohm) for one year from the
date of taking it into service. This should be confirmed.

Earthing System Inspection Chamber

a). Earthing system inspection chamber (concrete box) as per drawing enclosed with lid cover approx 50
mm thick with pulling hook. On backside of cover, date of testing and average resistance value shall be
written with yellow paint of black background. Alternatively prefabricated earthing inspection chambers
with proper dimensions may also be used.
b). A masonry chamber with hinged cover plate on the ground for each plate earthing station shall be
provided. Bidder shall dispose off the debris and other material removed during the construction of
earth pit at a place designated by the purchaser
c). Grounding test terminal boxes shall be installed at an appropriate location suitable for testing the
earth resistance. Typical Inspection Chamber is shown in Figure below: Inspection Chamber Earthing
Conductor

GI Strip

a). Supply and installation of tinned GI strips on the floor/wall/ceiling/ trenches with suitable size
spacer and saddle (Brass) and termination of copper strip at both ends (earthing plate as well as earth
bus) shall be carried out with brass bolts and nuts etc. Two separate distinct strips shall be run from
each earthing station upto the earthing bus available in the building.
b). The tinned GI strip shall be of ETP grade and conform to IS:191-Part-V. In this regard a test
certificate shall be supplied along with the delivery of copper material.
c). The earth conductors shall be fixed to the wall/columns etc., at every 500mm with brass spacers.
The total earthing system shall be mechanically and electrically connected to provide independent path
to earth.

Equip-potential earth bus bars:

There shall be one equi-potential earth bus bar(EEB) for each of the equipment room. The Equi-
potential earth bus bars located In individual equipment rooms shall be termed as Sub Equi-potential
bus bars(SEEB). The EEBs shall have pre-drilled holes of suitable size for termination of bonding
conductors. The EEBs shall be insulated from the building walls. Each EEB shall be installed on the wall
with low voltage insulator spacers of height 60mm. The insulators used shall have suitable insulating
and fire resistant properties for this application. The EEBs shall be installed at the height of 0.5m from
the room floor surface for ease of installation & maintenance. All terminations on the EEBs shall be by
using copper lugs with spring washers. Earth Resistance The earth resistance of combined earth system
shall be less than or equal to 1ohm. It shall be measured by an approved earth testing apparatus for
individual earth pits. Testing and measurement of earthing resistance as per IS: 3043.