Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
user’s manual
of
Construction
(part two)
Sub-Stations
Volume-3
Switchyard Erection
Construction Management
1.O INTRODUCTION 1
ANNEXURE - I
IN 1984 17
ANNEXURE - II
ASSOCIATED SYSTEMS
2.0 INTRODUCTION
2.2 LEVELLING
2.3 FOUNDATIONS
REACTORS
CHAPTER THREE
SWITCHYARD EARTHING
3.0 INTRODUCTION
IN SUBSTATION 45
3.8 JOINTING 48
CHAPTER FOUR
SWITCHYARD STRUCTURES
4.0 INTRODUCTION 54
SWITCHYARD 54
4.3 STORAGE 55
4.4 ERECTION 55
5.0 INTRODUCTION 62
5.2.1 ACSR 63
5.2.2 ALUMINIUM 63
OUTDOOR SUBSTATION 64
5.4 RECEIPT AND INSPECTION OF MATERIAL
AT SITE 64
INSULATORS 66
DURING ERECTION 68
QUALIFICATIONS 69
6.0 INTRODUCTION 78
6.2 STRINGING 79
CHAPTER SEVEN
SURGE ARRESTER
7.0 INTRODUCTION 86
7.4 INSTALLATION 89
CHAPTER NINE
CURRENT TRANSFORMER
9.0 INTRODUCTION 109
9.1 CONSTRUCTION FEATURES 109
9.2 HERMETIC SEALING 111
9.3 TRANSPORTATION, UNPACKING & INSPECTION 111
9.4 INSTALLATION/ERECTION 112
9.5 DO'S DONT'S & SPECIAL PRECAUTIONS 114
9.6 CHECK FORMAT 115
CHAPTER TEN
CAPACITIVE VOLTAGE TRANSFORMER
10.0 INTRODUCTION 117
10.1 DESCRIPTION & OPERATING PRINCIPLE 117
10.2 PACKING AND TRANSPORTATION 119
10.3 RECEIVING 120
10.4 UNLOADING 120
10.5 STORAGE 121
10.6 INSTALLATION 122
10.7 CONNECTION 122
10.8 DO'S, DONT'S AND SPECIAL PRECAUTIONS 125
10.8.1 INSPECTION BEFORE MOUNTING 125
10.8.2 DEFECT/DAMAGE 126
10.8.3 MINOR IRREGULARITIES 127
10.8.4 ERECTION 127
10.9 CHECK FORMAT 128
CHAPTER ELEVEN
POWER LINE CARRIER COMMUNICATION
11.0 INTRODUCTION 129
11.1 PLC SYSTEM 129
11.2 COUPLING EQUIPMENT 129
11.3 COUPLING EQUIPMENT DESCRIPTION 130
11.4 CONSTRUCTION FEATURES 130
11.5 DATA TRANSMISSION 131
11.6 TELEPROTECTION 131
11.7 CARRIER PANEL 131
11.8 EARTHING 131
11.9 ERECTION OF PLCC AND ASSOCIATED
EQUIPMENT 132
11.9.1 OUTDOOR EQUIPMENTS 132
11.9.2 INDOOR EQUIPMENTS 134
11.10 CONNECTION OF HF CO-AXIAL CABLE 136
11.11 INSTALLATION OF EQUIPMENT AS PER
PLANNED SYSTEM 137
11.12 DEFECTIVE MODULES AND FAULT
RECTIFICATION AT SITE 137
11.13 DO'S, DON'TS AND SPECIAL PRECAUTIONS 139
11.14 CHECK FORMAT 141
CHAPTER TWELVE
CABLES
12.0 INTRODUCTION 143
12.1 RECEIPT, INSPECTION AND STORAGE 144
12.2 CABLE LAYING IN SWITCHYARD 144
12.2.1 CABLE LAYING IN UNDERGROUND
(BURIE TRENCHES) 145
12.2.2 CABLE LAYING IN CABLE TRAYS 145
12.3 CABLE TERMINATION 146
12.4 DO'S DON'TS AND SPECIAL PRECAUTIONS 148
12.5 CHECK FORMAT 152
CHAPTER THIRTEEN
CONTROL AND RELAY PANELS
13.0 INTRODUCTION 154
13.1 CONSTRUCTION FEATURES 155
13.2 SIMPLEX PANEL 156
13.3 DUPLEX PANEL 156
13.4 RECEIPT AND STORAGE AT SITE 156
13.5 ERECTION OF PANELS 157
13.6 MOUNTING ON PANELS 158
13.7 PANEL INTERNAL WIRING AND EQUIPMENTS
IN PANELS 158
13.8 PROVIDING TERMINAL BLOCKS 159
13.9 NAME PLATES AND MARKINGS 160
13.10 PANELS ACCESSORIES 160
13.11 EARTHING 161
13.12 DO'S DON'TS AND SPECIAL PRECAUTIONS 162
13.13 CHECK FORMAT
Chapter-1
ELECTRICAL SUBSTATION
________________________________________________________________________________
_
CHAPTER
ONE
________________________________________________________________________________
_
ELECTRICAL SUBSTATION
Back to contents page
1.0 Introduction
Back to contents page
An electrical Network comprises of the following systems:
Generating Stations
Transmission Systems
Receiving Stations
Distribution Systems
Load Points
In all these systems, the power flow of electrical energy takes place
through Electrical Substations. An Electrical Substation is an
assemblage of electrical components including busbars, switchgear,
power transformers, auxiliaries, etc. Basically an electrical substation
consists of a number of incoming circuits and outgoing circuits
connected to common busbar system. Busbars are conducting bars to
which a number of incoming or outgoing circuits are connected. Each
circuit has certain electrical components such as circuit-breakers,
isolators, earthing switches, current transformers, voltage transformers,
etc. These components are connected in a definite sequence such that
a circuit can be switched off/on during normal operation by
manual/remote command and also automatically during abnormal
conditions such as short-circuits.
A substation receives electrical power from generating station via
incoming transmission lines and delivers electrical power via the
outgoing transmission lines. Substations are integral parts of a power
system and form important links between the generating stations,
transmission and distribution systems and the load points.
1.1 Functions of a sub-station:
Back to contents page
An electricity supply undertaking generally aims at the following:
Supply of required electrical power to all the consumers
continuously at all times.
Maximum possible coverage of the supply network over the given
geographical area.
Maximum security of supply.
Shortest possible fault duration.
Optimum efficiency of plants and the network.
Supply of electrical power within targeted frequency limits.
Supply of electrical power within specified voltage limits.
Supply of electrical energy to the consumers at the lowest cost.
As a result of these objectives, there are various tasks which are
closely associated with the generation, transmission, distribution and
utilisation of the electrical energy. These tasks are performed by
various, manual, semi-automatic and fully automatic devices located in
generating stations and substations.
The tasks associated with a major substation in the transmission
system include the following:
Controlling the exchange of energy
Protection of transmission system
Ensuring steady state and transient stability
Load shedding and prevention of loss of synchronism.
Maintaining the system frequency within targeted limits
Voltage control, reducing the reactive power flow by
compensation of reactive power, tap-changing.
Securing the supply by providing adequate line capacity and
facility for changing the transmission paths.
Data transmission via power line carrier for the purpose of
network monitoring, control and protection.
Determining the energy transfer through transmission lines and
tie-lines.
Fault analysis and pin-pointing the cause and subsequent
improvements.
Securing supply by feeding the network at various points.
All these tasks are performed by the team work of load-control centre
and control rooms of substations. The substations perform several
important tasks and are integral part of the power system.
1.2 Voltage Levels in AC Substations and HVDC Substations
Back to contents page
A substation receives power via the incoming transmission lines and delivers
power via the outgoing lines. The substation may have step-up
transformers or step-down transformers. Generally the switchyards at
sending-end of lines have step-up transformers and switchyards at
receiving-end have step-down transformers. The rated voltage level
refers to nominal voltage of 3 phase AC system and is expressed as
r.m.s. value between phases. An AC substation has generally 2 or 3
main voltage levels. The long distance transmission is generally at
extra high voltages such as 132 kV, 220 kV, 400 kV AC The
subtransmission is at medium high voltage such as 33 kV, 11 kV AC.
In a generating station, the generator is directly connected to step-up
transformer and secondary of the step-up transformer is connected to
outdoor EHV switchyard. The switchyard in a generating station
comprises generator transformer, unit auxiliary transformer and several
out-going lines. In addition to the main EHV switchyard, a generating
station has indoor auxiliary switchgear at two or three voltages such as
11 kV, 400 Volts.
The factory substations receive power at distribution voltage such as
11 kV and step it down to 440 volts AC. Larger factories receive power
at 132 kV and have internal distribution at 440 volts AC.
The choice of incoming and outgoing voltages of substations is decided
by the rated voltages and rated power of corresponding lines. Long
distance and high power transmission lines are at higher voltages. The
nominal voltages are selected from the standard values of rated
voltages specified in Indian Standards or relevant national standard.
The standards also specify the following reference values for each
voltage level.
Nominal voltage e.g. 220 kV, 400 kV
Highest system voltage, e.g. 245 kV, 420 kV
Lowest system voltage, e.g. 200 kV, 185 kV.
Table 1: Reference Values of Nominal Voltages in AC and HVDC Substations
AC Substation
765 kV, 400 kV, 220 kV, 132 kV, 66 kV, 33 kV, 11 kV
HVDC Substation
+400 Kv, +500 kV, +600 kV
Station Auxiliaries
Aux. AC Supply : 33 kV, 11 kV
400 V, 3 ph., phase to phase
230 V AC single phase
Aux. LVDC : 220 V, 110 V, 48 V DC
1.0 Land
1.1 Size (Acre)
(Mtr. x Mtr.)
1.2 Govt. Private/Forest land
1.3 Agriculture/Wasteland
1.4 Development
1.5 Approximate cost
1.6 Type of soil
1.7 No. of owners
1.8 Environment/Pollution in the vicinity
1.9 Location with reference to nearest town
1.10 H.F.L. Data
1.11 Diversion of Nallah/Canal required
1.12 Slope
1.13 Extent of levelling required
1.14 Land acquisition feasibility
1.15 Rate of Govt. land
1.16 No. of owners
1.17 Exten. of approach
1.18 Planned/unplanned development
1.19 Size of sites
1.20 No. of families displaced
1.21 Required Government value
1.22 Level of site with ref. to road level
1.23 Distance from sea shore
2.0 Approach
2.1 What are the Obstacles in reaching site
2.2 Approach road
2.3 Length of approach road
2.4 Distance from main road
2.5 Unloading facility at Railway Station
2.6 No. of Culverts required
3.0 Community Facilities
3.1 Drinking Water
3.2 Drainage
3.3 a) Post Office
b) Telephone
c) Telex
3.4 Market
3.5 Security
3.6 Amendability
3.7 Availability of construction water
3.8 Availability of water
3.9 Nearest EHV line
3.10 Length of line between
this site & nearest substation
3.11 Length of line estimate
3.12 Additional crossings
3.13 Frontage for line take off
3.14 Telephone/Telegraph line
4.0 Others
1.6.1 Land Acquisition
Back to contents page
Land is a state subject. Land acquisition activity starts after the
approval is obtained from the competent authority for the
recommended site. Land is to be acquired for starting the construction
activities. Typically for a 400 kV sub-station 50-80 Acre land is
required. Land being the state subject, acquisition for the sub-station
land is carried out through land acquisition deptt. of the concerned
state govt.
Brief summary of Land Acquisition Process is given below
1.6.2 Provisions Under The Land Acquisition Act, 1894 For Sub-Stations
Back to contents page
When land is acquired for sub-stations, POWERGRID will follow
procedures laid down under the Land Acquisition Act (LA Act), 1894.
POWERGRID sub-stations have never resulted in large scale
displacement or loss of livelihoods. There have been only marginal
impacts due to flexibility exercised by POWERGRID in selecting sites.
The LA Act specifies that in all cases of land acquisition, no award of
land can be made by the government authorities unless all
compensation has been paid. POWERGRID has always followed a
schedule for R&R (illustrated in Table below). These will be further
reinforced taking into consideration POWERGRID’s entitlement
framework and public consultation process.
Table 4: POWERGRID’s Activity Chart for Land Acquisition
and R&R Activity
i) Circuit Breakers
Circuit Breakers are the switching and current interrupting
devices. Basically a circuit-breaker comprises a set of fixed and
movable contacts. The contacts can be separated by means of
an operating mechanism. The separation of current carrying
contacts produces an arc. The arc is extinguished by a suitable
medium such as dielectric oil, vacuum, SF6 gas. The circuit
breakers are necessary at every switching point in the
substation.
ii) Isolators
Isolators are disconnecting switches which can be used for
disconnecting a circuit under no current condition. They are
generally installed along with the circuit breakers. An isolator
can be opened after the circuit breaker. After opening the
isolator, the earthing switch can be closed to discharge the
trapped electrical charges to the ground.
iii) Current Transformers and Voltage Transformers
These transformers are used for transforming the current and
voltage to a lower value for the purpose of measurement,
protection and control.
iv) Surge Arresters
Surge Arresters divert the over voltages to earth and protect the
substation equipment from over voltage surges.
v) Busbars
Busbars are either flexible or rigid. Flexible busbars are made
of ACSR conductors and are supported on strain insulators.
Rigid busbars are made up of aluminium tubes and are
supported on post insulators.
vi) Galvanised Steel Structures
Galvanised Steel Structures are made of bolted/welded
structures of angles/channels/pipes. These are used for towers,
gantries, equipment, support structures etc. Galvanised
structures provide rigid support to the various equipments and
insulators. The design should be safe and economical.
vii) Power Line Carrier Current Equipment
PLCC is necessary for transmitting/receiving high frequency
signals over the power line (transmission Line) for the following:
a) Voice communication
b) Data transmission
c) Protection signalling
d) Control signalling
A small power system is generally controlled by direct
supervision of generating stations and substations through
respective control rooms. A large network having several
generating stations, substations and load centres is controlled
from central load despatch centre. Digital or voice signals are
transmitted over the transmission lines via the substations. The
substations are linked with the load control centres via Power
Line Carrier System (PLCC)/ microwave links and P&T phones.
The data collected from major substations and generating
stations is transmitted to the load control centre. The
instructions from the load control centres are transmitted to the
control rooms of generating stations and substations for
executing appropriate action. Modern power system is controlled
with the help of several automatic, semi-automatic equipments.
Digital computers and microprocessors are installed in the
control rooms of large substations, generating stations and load
control centres for data collection, data monitoring, automatic
protection and automatic control.
viii) Protective Systems in Substations
A fault in its electrical equipment is defined as a defect in its
electrical circuit due to which the flow of current is diverted from
the intended path. During the fault the impedance is low and
fault current is high. Fault currents being high, can damage the
equipments thro’ which it flows.
Fault in certain important equipment can affect the stability of
the power system. For example, a fault in the bus zone of a
substation can cause tripping of all the feeders and can affect
the stability of the interconnected system.
The relays distinguish between normal and abnormal condition.
Whenever an abnormal condition develops, the relay closes its
contacts. Thereby the trip circuit of the circuit breaker is closed.
Current from the battery supply flows in the trip coil of the circuit
breaker and the circuit breaker opens and the faulty part is
disconnected from the supply. The entire process, ‘occurrence
of fault-operation of relay opening of circuit breaker to removal
of faulty part from the system’ is automatic and fast. Besides
relays and circuit breakers, there are several other important
components in the protective relaying scheme, these include :
protective current transformers and voltage transformers,
protective relays, time delay relays, auxiliary relays, secondary
circuits, trip circuits, auxiliaries and accessories, etc. Each
component is important. Protective relaying is a team work of
these components.
The function of different substation equipments and systems
are tabulated below in Table -5.
Table 5: Functions of different Substation Equipments & Systems
J. Structural arrangement
1. Design of towers and beams
2. Fabrication drawings of tower & beams
3. Tower foundation and their designs
4. Design of equipment supporting structure
a) CT
b) CVT
c) LA
d) Bus Post Insulator
e) Isolator
f) Wave Trap
g) Circuit Breaker
5. Equipment supporting structure fabrication drawings
a) CT
b) CVT
c) LA
d) Bus Post Insulator
e) Isolator
f) Wave Trap
g) Circuit Breaker
6. Details of foundation bolts
a) Equipment Structure
b) Gantry Structure
7. Design of equipment foundations & foundation details
8. Cable trench layout
9. Cable trench section details
10. Cable trench road crossings
11. Marshalling box foundation
12. Sump pit
List of construction Drawings for Township Work in a typical Sub-station
2.0 Introduction
Back to contents page
Civil works in a substation mainly comprise of :
Construction of equipment foundations transformer/reactor plinth,
structure foundations
Cable trenches
Fencing around switch yard
Surface treatment, ground filling and sloping
Water supply system & Sewerage system
Construction of roads and drains
Construction of control room building, compressor room, offices,
repair / maintenance bay and other non-residential buildings
Construction of railway, siding and railway track if required
Construction of residential colony
Horticulture works
Administrative Building, community centre, guest house/transit
Camp, shopping complex & nursery school etc.
For carrying out the various civil works at site which is initially an open
barren/cultivated land, initially survey of land is carried out alongwith
the soil investigation. Survey is done to finalise the levels of switchyard,
roads and design & layout of drainage system in the switchyard as well
as in the township. Fix & permanent bench mark is provided for
adopting it as a reference point for various works like laying out of
control room, erection of gantries and various equipments, foundations
and buildings in the switchyard that are done in reference to this
permanent bench mark. Now grid lines are required to be marked in
East-West and North-South direction by erecting the concrete grid
pillars. Grid lines are marked on the land to fix the direction &
orientation of various civil structures with reference to some fixed
bench mark on the site. These gridlines help in implementing the
erection, orientation and layout of foundations for various equipments &
control room building which is later on helpful in laying out the other
equipments and structures on the land.
2.1 Soil Investigation
Back to contents page
SWITCHYARD EARTHING
Back to contents page
3.0 Introduction
Back to contents page
The object of earthing is to maintain a low potential on any object. The
purpose of a earthing system in a substation area is to limit the
potential gradient within and immediately outside the area to a value,
safe for the working personnel. Safety is to be ensured under normal
as well as abnormal operating conditions.
3.1 Functional Requirements of Earthing System
Back to contents page
3.8 Jointing
Back to contents page
i)Earthing connections with equipment earthing pads are bolted type. Two bolts are
provided for making each connection. Equipment bolted connections, after being
checked and tested are painted with anti-corrosive paint/compound of specified
material.
ii)Resistance of Joint should not be more than the resistance of the equivalent length
of the conductor.
iii)All ground connections are made by electric arc welding. All welded joints are
allowed to cool down gradually to atmospheric temperature before putting any load
on it. Artificial cooling is not allowed.
iv)Each earthing lead from the neutral of the power transformer/reactor is directly
connected to two pipe electrodes in treated earth pit (as per IS) which in turn, are
buried in Cement Concrete pit with a cast iron cover hinged to a cast iron frame to
have an access to the joints. All accessories associated with transformer/reactor like
cooling banks, radiators etc. are connected to the earthing grid at minimum two
points.
v)Earthing terminals of each lightning arrester & Capacitor Voltage Transformer is
directly connected to rod earth electrode which in turn is connected to station
earthing grid.
3.9 Measurement of Earth Resistance
Back to contents page
Three electrode methods is used for measuring the earth resistance in
switchyard (Fig. 14). To measure the earth resistance both C1 and P1
terminals of megger could be connected to a spike that is driven in
ground and connected to earth mat whereas terminals P2 and C2 are
connected to the equidistant spikes driven in ground (not connected to
earth mat). The value of of R could be read in the scale with the
rotation of the handle of megger or press of a button. This will give the
value of earth resistance. The value as far as possible should be below
1 ohm. In case this value is high water should be sprinkled in the
earthing pits for improvement of earth resistance.
DO’S DON’TS
&
SPECIAL PRECAUTIONS
3.10 Do’s Don’ts and Special Precautions
Back to contents page
i) Metallic conduits should not be used as earth continuity conductor.
ii) Wherever earthing conductor crosses or runs along metallic
structures such as gas, water, steam conduits, etc. and steel
reinforcement in concrete it should be bonded to the same.
iii) Flexible earthing connectors should be provided for the moving
parts.
iv) Steel to copper connections should be brazed type and treated to
prevent moisture ingression.
v) Sheath and armour of single core power cables should be earthed
at switchgear end and equipment side.
vi) Contact surface of earthing pads for jointing free from scale, paint,
enamel, grease, rust or dirt.
vii) Earthing conductors or leads along their run on cable trench ladder,
columns, beams, walls etc. should be supported by suitable
welding/cleating at intervals of 750 mm/ as specified.
viii)Light poles, junction boxes on the poles, cable and cable
boxes/glands, lockout switches etc. are connected to the earthing
conductor running alongwith the supply cable which inturn is
connected to earthing grid conductor at a minimum two points
whether specifically shown or not
ix) Earthing conductor is generally buried 2000 mm outside the
switchyard fence. All the gates and every alternate post of the
fence is be connected to earthing grid.
x) Meggar used for measuring soil resistivity should be calibrated with
great accuracy. In case if an accurately calibrated meggar is not
available, 2 or 3 different meggars should be used to take same set
of readings.
xi) The earth resistivity should be taken in dry weather condition.
xii) For transformer & shunt reactor earthing, earth pits of 3-4 m depth
below the ground with 40 mm dia GI pipe & specified quantity of salt
and coke should be provided.
xiii)The earth resistance should also be measured after completion of
laying of earth mat and earth electrodes by the same 4 electrode
methods for complete system, individual earth pits & earth rod
electrodes.
xiv)The measured value of combined earth resistance should not be
more than 0.5 ohm.
xv) For earth electrodes and individual earth pits, this value can be upto
1 ohm.
xvi)In case these values are not being achieved water should be
poured in earth pits to bring the earth resistance within the specified
range.
CHECK FORMAT
3.11 Check Format
Back to contents page
SWITCHYARD STRUCTURES
Back to contents page
4.0 Introduction
Back to contents page
lattice type and pipe type structures. With both these type of structures,
and other bolts & nuts is also linked up. Efforts should be made such
one or the other item. Various aspects right from the scope of work to
support for gantry and various equipments like CT, CVT, LAs etc. The
structure supports also include the cap and base plates, stiffeners,
identification marks as per the delivery challan/ packing list etc. One
supplier.
4.3 Storage
Back to contents page
proper tags depicting the size, quantity, code no., supplier name
etc.
iv) In case the store building is not ready, the material may be kept
4.4 Erection
Back to contents page
iii) The erection work is carried out manually (by built up or piece meal
this purpose.
sequence.
vi) The cross braces of the first section which are already assembled
on the ground are raised one by one as a unit and bolted to the
vii) For assembling the second section of the towers, gin poles are
placed one each on the top of the diagonally opposite corner legs.
These two poles are used for raising parts of second sections.
erected.
ix) The lattice structure are used for various equipment erection in the
arrester.
xi) To maintain the proper level necessary shims are inserted in pipe
works.
xii) The beam erection work of tower is carried out at the ground by
block. Even winch machines can also be used for this purpose.
xv) One side of the beam is tightened first with the gantry structure on
one side. For finer adjustments winch machines can be used. This
cranes.
ii) During erection the top level of the pipe structure should be
maintained horizontal.
iii) This can be checked with the spirit level and shims can be used to
v) The persons doing erection of pipe structure should use the safety
Lightning masts are the highest angle iron structures in the switchyard.
ii) The lattice members, pipes etc. should be checked as per the BOQ
the switchyard.
iv) All safety procedures for erection work like use of safety helmets,
structure erection.
vii) Any bend members and pipes should not be allowed and
punching purpose.
erection.
done. Before carrying out the final punching it must be ensured that
that water does not stager on the members (water gate). Also,
erection.
should be used.
xvi)Steel rope of 3/8” dia of required length should be used with winch
machine.
xviii)Single sheave and double sheave pulleys should not be less than
structures.
CHECK FORMAT
4.5 Check Format
Back to contents page
1. All items have been checked with the packing list, MICC, Yes/No
Challans GR etc.
2. After unloading the visual inspection of the angles/members Yes/No
erection at site.
6. All pipes have been checked and found straight w.o. any bends Yes/No
or damage.
7. Bolts/nuts/spring, pack washers are stored in the closed room Yes/No
(in bags).
8. Proper tags depicting the size, quantity code no. and supplier Yes/No
bags.
9. During structure erection proper safety measures like helmets, Yes/No
personnel.
10. All lattice members are available (as per drawings) before start Yes/No
of erection.
11. Proper care in horizontal levelling of lattice structure for Yes/No
works.
13. Assembled beam (of gantry structure) is being lifted with crane Yes/No
site.
16. 2-3 threads of bolts are exposed out after tightening the nuts for Yes/No
punching purpose.
17. Proper sized bolts/nuts and pack washers are used in tower Yes/No
erections.
18. Verticality of tower is within the safe tolerance of 1 in 360. Yes/No
CHAPTER-5
BUSPOST INSULATORS & BUSBARS
___________________________________________________________________________
CHAPTER
FIVE
___________________________________________________________________________
5.0 Introduction
Back to contents page
The substation busbars can be broadly classified in the following three
categories:
i) Outdoor Rigid Tubular Busbars
ii) Outdoor flexible ACSR aluminium alloy busbars
iii) Indoor busbars
The busbars are designed to carry certain normal current continuously.
The cross-section of conductors is designed on the basis of rated
normal current and permissible temperature rise. The value of cross
section so obtained is verified for temperature rise under short-time
short-circuit current.
The busbar conductors are supported on post insulators or strain
insulators. The insulators experience electro-dynamic forces during
short circuit currents. These forces are maximum at the instant of peak
of first major current loop. These forces produce bending moment on
separated insulators. The spacing between adjacent insulators is
decided on the basis of bending moment per metre and strength of
insulators.
5.1 Steps in Busbar Design
Back to contents page
The busbar design is carried out in the following steps:
i) Choice of cross-section of conductor based on required normal
current, given ambient temperature and specified permissible
temperature rise.
ii) Calculation of temperature rise under short time current to see that
it is in safe limits.
iii) Calculation of electro-dynamic forces per metre for given short
circuit current.
iv) Calculation of choice of support insulators on the basis of bending
moment withstand value.
v) Calculation of span of support insulators on the basis of the force,
bending strength of insulators and factor of safety.
vi) Design of insulator system, phase to phase clearance, phase to
ground clearance and creepage.
vii) Design of support structures.
viii)Design of clamps and connectors, flexible joints.
5.2 Forms of Busbars
Back to contents page
Busbars of Outdoor Switchyard are in the following forms:
ACSR conductors supported at each end on strain insulators.
Tubular Aluminium Conductors supported on post insulators
made of porcelain. These are either welded to get extended
lengths.
Busbars for Indoor Switchgear are in the form of aluminium or
copper flats. These are supported on epoxy cast insulators.
5.2.1 ACSR
Back to contents page
ACSR conductor to be used for busbars is supported on insulators. As
most of the equipments can be installed below the flexible bus, land
requirements are also less. The cost of this scheme is lower due to
less no. of support structures.
5.2.2 Aluminium
Back to contents page
Aluminium is used for busbars in indoor and outdoor switchgear.
Aluminium and aluminium castings (5 to 12% silicon) are used in
busbar. Aluminium is used in the form of strips /rectangular bars for
busbar application. While using aluminium for busbars, the difficulties
arise due to the following aspects:
i) Higher resistivity, hence associated problems of temperature rise.
ii) Lower tensile strength than copper.
iii) Lower thermal conductivity than copper.
iv) Higher coefficient of linear expansion than copper.
v) Higher joint resistance and associated problems about joining.
vi) Special welding techniques are necessary.
5.3 Configuration of Busbars in Outdoor Substation
Back to contents page
The conductors of a busbars systems in an outdoor substation are of
the following two types:
i) Rigid aluminium tubular bus conductors supported on post
insulators
ii) Flexible ACSR supported on strain insulators. The conductors of
three phases of each bus are placed in horizontal configuration.
Table 1: Comparison between Rigid Bus System and Flexible Bus System
_____________________________________________________________
Positions (QW-405)
Position of groove :
Welding progression :
_____________________________________________________________
Preheat (QW-406)
Preheat temperature min.
Interpass temperature max.
Preheat maintenance
_____________________________________________________________
Post weld heat treatment (QW-407)
Temperature range
Time range
____________________________________________________________
Gas (QW-408)
Shielding gas
Percent composition (mixture)
Flow rate
Gas backing
Trailing Shielding gas composition
_____________________________________________________________
_____________________________________________________________
Electrical characteristics
Current AC or DC
Amps (Range)
Tungston electrode size and type
Mode of metal transfer for GMAW
Electrode wire feed speed range
_____________________________________________________________
Technique (QW-410)
String or weave bead
Orifice or gas cup size
Initial and interpass cleaning
Method of back gauging
Oscillation
Contact tube to work distance
Multiple or single pass (per side)
Multiple or single electrode
Travel Speed (Range)
Peening
Other
_________________________________________________________________
Weld Process Filler Class Metal dia Current Voltage Travel Speed
Others Range
Layer Type Amp
Polar Range
Annexure - II
DATA - FORMS
QW-484 SUGGESTED FORMAT FOR MANUFACTURER’S RECORD OF
WELDER OR WELDING
OPERATOR QUALIFICATION TESTS
Welder Name _________________ Check No. __________ Stamp No. _______
Welding Process __________________ Type ______________________________
In accordance with Welding Procedure Specification (WPS) ___________________
Backing (QW-402) ___________________________
Material (QW-403) Spec. ______ To ______ of P.No. ______ to P.No. ________
Thickness _______ Dia _______
Filter Metal (QW-404) Spec. No. _________ Glass No. _________F No. _________
Other _____________________________
Position (QW-405) (1G, 2G, 6G) ________________________________________
Gas (QW 408) Type _______________ % Composition _____________________
Electrical Characteristics (QW 409) Current _________________ Polarity _______
Weld Progression (QW-410) __________________________________________
Other _____________________________________________________
For Information Only
Filler Metal Diameter and Trade Name _________________________
Submerged Arc Flux Trade Name _________________________
Gas Metal Arc Welding Shield Gas Trade Name _______________________
6.0 Introduction
Back to contents page
and from the last tower on the lines to the first gantry structure. The
a transmission line even then the site should take care of the following
cracks
iii) Insulators should be clean from dust or other foreign materials.
iv) Conductor should not be allowed to lie or rub on the ground during
paying/pulling.
v) Nuts and bolts of all gantry structure should be checked and the
6.2 Stringing
Back to contents page
ii) The final sagging is done by using winch machines. The winch
iii) Final adjustment of conductor is done upto the desired point that
compression machine.
suspension clamps.
vii) Spacers are provided between twin conductors after final sag is
completed.
Hydraulic/manual compression
desired
D -Shackle - 8 nos.fs
reqmt.
-
160 kN porcelain/glass insulators
do -
Spacers
do -
DO’S DON’TS
&
SPECIAL PRECAUTIONS
6.4 Do’s Dont’s and Special Precautions
Back to contents page
ii) Insulator string should be pulled in such a way that it does not
helmets.
removed.
vi) Conductor should be cut at the marked point and dead end joint
be provided.
ix) Insulators should be completely cleaned with soft and clean cloth.
x) It should be verified that there is no crack or any other damage to
insulators.
xi) It is very important to ensure that ‘R’ clips in insulator caps are
insulator discs.
xiv)It should be verified that all nuts and bolts are tightened properly.
xv) It should be ensured that all the necessary security pins (split pins)
by winch machine fixed on tower leg until the desired final sag is
achieved.
xx) Conductor should be cut at the marked point and dead end joint be
possible.
works.
approved drawings.
xxxiii)In case of Tension fitting dead end joint dimensions before and
1. Towers are tightened properly and all the members, Nut/Bolts Yes/No
on ground/hard surfaces.
5. Sag is measured correctly at prevailing temperature. Details Yes/No
are recorded.
6. After measuring sag, marking/cutting of Earthwire/ conductor is Yes/No
are OK.
10. All components of fittings have been checked up for Yes/No
has been taken that insulators are not broken during lifting.
12. Care has been taken so that conductor while pulling is not Yes/No
damaged.
13. Proper sag and tension have been maintained as per the day Yes/No
sag.
15. All nuts & bolts of jumper fittings have been tightened properly. Yes/No
16. Jumper spacers have been provided. Yes/No
17. Spacers have been provided as per the spacer placement Yes/No
chart.
18. Care has been taken to avoid any overtensioning. Yes/No
19. R. Clips of the insulators in insulator string have been properly Yes/No
provided.
20. In both suspension and double tension fitting the split pin have Yes/No
parabolic shape.
22. In case of tension fitting dead end joint dimensions before & Yes/No
SURGE ARRESTER
Back to contents page
7.0 Introduction
Back to contents page
Surge Arrester is a device designed to protect electrical equipments
from high voltage surges and to limit the duration and amplitude of the
follow current. Surge arresters are used to protect Power System
Installations and equipments against lightning overvoltages also.
Generally arresters are connected in parallel with the equipment to be
protected, typically between phase and earth for three phase
installations.
The main element of a surge arrester is the ‘Non-Linear Resistor’, the
part of the arrester which offers a low resistance to the flow of
discharge current thus limiting the voltage across the arrester terminals
and high resistance to power frequency voltage, thus limiting the
magnitude of follow current.
There are 2 types of designs available for EHV Surge-Arrester. These
are Conventional gapped Surge-Arrester (Value Type) and Metal Oxide
Surge-Arrester.
7.1 Conventional Gapped Lightning Arrester (Valve Type Arrester)
Back to contents page
In a substation the Surge Arrester is connected between line and earth.
It is the first apparatus as seen from the overhead transmission line
entering in the switchyard. It consists of resistor elements in series with
gap elements offer non-linear resistance such that for normal
frequency power system voltages the resistance is high however, for
discharge currents the resistance is low. The gap units consist of air
gaps of appropriate length. During normal voltage4s the lightning
arrester does not conduct. When a surge-wave travelling along the
Overhead line comes to the arrester, the gap breaks down. The
resistance offered being low the surge is diverted to the earth. After a
few micro seconds the surge vanishes and normal power frequency
voltage is set up across the arrester. The resistance offered by
resistors to this voltage is very high. Therefore, are current reduces
and voltage across the gap is no more sufficient to maintain the arc.
Therefore, the current flowing to the earth is automatically interrupted
and normal condition is restored. The high voltage surge is discharged
to earth. Hence the insulation of equipment connected to the line is
protected.
7.2 Metal Oxide Lightning Arresters
Back to contents page
The metal oxide arresters without spark gaps consist of an active part
which is a highly non linear ceramic resistor made of essentially Zinc
Oxide. Fine Zinc Oxide crystals are surrounded by other metal oxides
(additives). Such microstructures render extreme non-linear
characteristics to these ceramic resistors.
In the operating characteristic of Surge Arrester the current axis is in
logarithmic scale. The current increases by 107 orders of magnitude
when the voltage across element doubles. This special characteristics
is the heart of protection technology in this type of Surge Arrester.
The lower linear part ‘A’ is temperature dependant and exhibits a
negative temperature coefficient. The arrester is designed in such a
way that the applied operating voltage gets located around point ‘O’.
This results in a continuous resistive curent of few micro amps flowing
through the resistor elements. Under over voltage condition, the
voltage increases and shifts operating pont momentarily for
overvoltage duration to point near ‘B’. This results in a resistive current
of few milli-Amperes flowing through the resistor elements. As soon as
the overvoltage disappears the operating point shifts back to ‘O’. In the
event of transient switching or lightning vervoltages, the operating point
will shift to portion ‘C’. For the transient of a few micro seconds it will
draw current in the range of 5/10 k Amps. In the event of very high
lightning current of the order of 40 to 100 k Amps peak, the operating
point will shift to portion ’D’. However, on expiry of transient of few milli
seconds the operating point will come back to point ‘O’.
Thus the operating point of these arresters is normally located at point
‘O’ called Maximum Continuous Operating Voltage (MCOV) and the
point ‘B’ of the Fig. (5) indicates approximately the rated voltage of
arrester. The arrester can stay at point ‘O’ i.e., MCOV, all long its life
but can stay at point ‘B’ (fault condition), i.e. Rated Voltage, for only 10
seconds (it is presumed that system breakers will operate to isolate the
fault within 2 seconds). The energy that gets dissipated, I.e. (I2R)
during continuous or overvoltage condition decides the size (dia) of
ZnO resistor element. These are classified as different classes
depending upon the energy handling capabilities. Higher class
corresponds to higher energy capability.
7.3 Packing, Transport, Handling And Storage
Back to contents page
(i) Las are packed vertically on sturdy wooden case. For reasons of fragile
porcelain, care should be taken while unpacking, handling and installation
so as to avoid impact with hard surface.
(ii) Immediately on receipt, inspect the cases for signs of transhipment or
physical damages packings. In case of any damage matter should be
reported to insurance company as well as the manufacturer for guidance.
(iii) At site the Surge Arrester should e stored in the original packing case and it
should also be ensured that boxes are kept in the original vertical condition.
(iv) While taking out of the cases too, Arrester units should be placed in upright
position, the porcelain sheds facing down.
(v) As LAs are assembled in controlled condition, no attempt should be made at
site to open or repair the arrester without consultation of the manufacturer.
(vi) It is recommended to use nylon ropes for handling the arrester at site.
7.4 Installation
(i) Fix base plate with 4 bolts (if it was not already fixed) to LA bottom.
(ii) Base insulators should be placed loosely on the mounting plate of structure.
(iii) Fix the Surge Counter mounting bracket alongwith one of the base insulator
to the structure.
(v) Lower the Arrester unit and use base insulator stud \ bolt to guide it in place.
(viii) Connect the stud at the back of Surge Counter to base plate by the
connecting link.
(ix) When surge counter is not in use, base plate should be positively connected
to earth.
(ii) Loosen and remove 4 bolts from top of the top units.
(iii) Fix the corona ring to the top of the top unit / middle unit using
(iv) Loosen and remove 4 bolts from top of the bottom unit (& Middle
(v) Lift the Top unit and engage 4 studs at the bottom.
(vi) Lower the top unit to the top of bottom unit (or middle unit in
(vii) Fix the units in place. (In case of 3 stack LAs fix the top & middle
(x) Fix the Surge Counter mounting bracket with one of the bolts.
substation.
(xii) Ensure that structure is earthed with the earth mat in the
substation.
(xiv) Fix surge counter on the bracket and connect the stud at the
conductor.
DO’S DON’TS
&
SPECIAL PRECAUTIONS
7.7 Do’s, Don’ts & Special Precautions
(i) Slack span stringing from dead end tower to the gantry should
(iv) Use of flexible copper strips between the bushings and earth
(v) Proper care to prevent any damage to the surge bushing should
be taken.
Challans GR etc.
3. After unloading the visual inspection of the packings has been Yes/No
mat.
___________________________________________________________________
CHAPTER
EIGHT
___________________________________________________________________
ISOLATOR
Back to contents page
CHAPTER-8
8.0 Introduction ISOLATOR
Back to contents page
the circuit under no load conditions. They are installed in such a way
that a part of substation circuit can be isolated from other live parts for
lines.
i) Support Structure
ii) They have the arrangement to fix over the foundation for fixing the
iv) These structures are designed to withstand all forces like short
drive arrangement
ii) Stoppers are provided in both ends to control the travel of Moving
galvanised
requirement.
ii) The male and female contacts (reverse loop design) are made of
iii) The Connecting Stem is made out of electrolytic copper with Tin
Plating/Aluminium.
iv) The current transfer part that connects the Aluminium housing and
stem is made out of Copper with Tin plating and assembled inside
the Housing.
action with adequate number of NO, NC and long wipe contacts are
provided.
ii) Front door of the mechanism box is provided with good quality
the boxes are metal treated before being taken up for painting.
auxiliary wiring.
iii) Moving Blade of earth switch is made out of aluminium tube and
logging.
8.4 Erection/Installations
Back to contents page
8.4.1 Structures
Back to contents page
iii) Structure assembly is lifted and fixed over the plinth (Without
iv) Assemble washer, spring washer and nuts in all foundation bolts.
v) Check for level at the top of the structure in both directions by using
spirit levels. If required give shims below the base plate of structure
drawing.
ii) Lift the base assembly by using proper ropes and place it over the
relevant structure
iii) After keeping it over the base without removing the rope align it to
the mounting hole of base and top plate of structure and fix the
iv) Check for level of flanges in both direction by using spirit level.
v) If necessary add shims below the leg of the base and align it.
vii) Repeat the installation process for other two poles also.
viii)Ensure the Centre line of same pole and centre line of other
ix) After completing the installation keep all the base assemblies in
open position
8.4.3 Insulators
Back to contents page
proper bolts and nuts. Lift the Insulator stack by using proper
hook and placed over the base assembly by ensuring the top 4
holes position.
iii) Without removing the hook align the holes and fix all bolts.
the bottom flange of the insulator or/and between two insulator unit
flanges .
v) Now rotate the shaft assembly & check for the rotation of insulator
vi) The same procedure is to be repeated for the other side of same
pole also
vii) In the same way the top unit of insulator and middle unit are
iii) Lift the Male Assembly by using proper sized rope and place it
iv) Without removing the rope align the holes and fix the screws.
vi) Rotate the bearing shaft assembly and check for alignment of
vii) If the entry is not smooth, loosen the contacts Mounting screws
viii) After achieving the entry check for centre line of Male and Female
in both directions.
proper alignment
xi) Moving part should be operated two to three times for checking
the free movement and also check that the contact corona ring
iii) Align the fixing hole and bolt them together to achieve desired
tightness.
iv) Ensure that the mounting channel on the drive and the structure
are matching.
v) Level the box by placing the spirit level on output shaft flange in
two directions.
vii) Check for centre line and verticality between torque bearing
Arrangement Drawing.
ix) Measure exact height between torque bearing flange and top of
universal flange.
smooth entry.
xiii) Before energising the circuitry, interlock wiring and control wiring
A hinged panel on the right hand side of the cabinet carries the
These comprise :
ii) In case of individual pole drives the master control cabinet will
ii) Once the associated circuit breaker is open, closing contact will
iii) Set the electrical remote selector to local position as required and
then press push button for closing, thereby causing the closing
iv) The hold on contact of closing contactor will now be closed there-
vii) The isolator will start to close, and at the end of the closing
operation, limit switch for closing will open then de-energising the
closing contactor.
viii) The circuit is now de-energised and the closing operation is
completed.
i) After single pole trial with motor keep that pole in closed
condition
ii) Fix other two poles also in closed condition (set the stopper
screws)
iii) Measure the distance between the lever of two adjacent poles
iv) Check and set the Tandem, pipe length on the floor itself
v) Lift the Tandem pipe by using proper rope and fix one side first
pins.
vii) Operate the operating mechanism and check for proper closing
viii) Repeat this process for the other poles ('Y' & 'B')
ii) Take the Earth fixed contact assembly and fix it with the Hamper
iii) Lift the Earth Blade Assembly by using rope and fix it with base
assembly in place.
ground.
add shims at the back of the mounting plate to tilt the earthing
that the contact fingers come into the fixed contact. A small
mounting plate.
vii) Continue to close earthing switch until contacts are fully engaged
i.e. when the insulated stop of the earthing blade comes to rest
viii) Tighten all fixing bolts and keep the earth switch in closed
position.
DO’S DON’TS
&
SPECIAL PRECAUTIONS
8.8 Do’s, Don’ts and Special Precautions
Back to contents page
iv) Cable glands should be properly fitted at the entry of the cables
vi) The bolts and nuts required for mounting the base to the structure
items, while all the other hardware (bolts & nuts) are fitted in their
i) Manual
ii) Electrical
stage.
e) Operate control Switch and at the same time observe whether the
position the isolator will open or close. Once the mechanism has
around the output shaft and cool air is sucked in. A switch is
mounted on the front of the control panel for the control of the
Fuses for the control and heater circuits are mounted on the
Challans GR etc.
3. After unloading the visual inspection of the packings has been Yes/No
of erection work.
6. Level of the structure assembly has been checked during Yes/No
of erection work.
8. Level of the top surface of isolators has been checked during Yes/No
checked
11. Before fitting, the crane rings have been identified for male and Yes/No
female assembly
12. Moving parts have been operated 2-3 times for checking the Yes/No
free movement
13. The rotation of motor is in right direction Yes/No
14. In case it is in opposite direction the same has been corrected Yes/No
contact
18. All fixing bolts have been tightened to keep the earth switch in Yes/No
CURRENT TRANSFORMER
Back to contents page
9.0 Introduction
Back to contents page
from higher value to lower value for measuring /protection /control. CTs
v) Rated burden
viii)Composite error
types:
Hair Pin design or dead tank type and Top dome design or Dead Tank
design. In the hairpin design the primary conductor enters from the top
wound on the primary inside the tank. The body of tank is earthed to
of this type. In the other top dome design the Primary conductor goes
wound against it. As the tank body is always live this design is known
design. As the head is heavy, more care is required while lifting and
coils and core. The core is constructed in the form of rings. The
The secondary terminals are brought out through a terminal board into
the terminal box. From terminal board the connections are given to the
blocks.
The outer surfaces of ferrous parts are given light grey enamel paint to
shade over rust inhibitive coat of ready mixed zinc chrome primer.
Steel surfaces coming in contact with transformer oil are given a coat
fasteners. All welded and gasket joints are subjected to leak tests.
drying chamber to extract the moisture from the insulation paper. After
hermetically sealed with dry Nitrogen gas above oil. When the oil
pressure at the time of initial filling are adjusted so that the gas
pressure will be less than + 0.5g/cm2 at 75oC and above -0.2 kg/cm2
position (with the oil level gauge side at the top) fixed to a
iii) For unloading /loading the crates, crane should be used in store
iv) CT at site should always be lifted from lifting brackets which are
bushings.
vi) After receiving at site CT should be checked for any physical
defect.
9.4 Installation/Erection
Back to contents page
and free from all dust, grease and particles of packing material.
spirit/water level.
vi) Now the crane can be removed after tightening the bolts & nuts.
viii) Lay the control cables from control room relay panels and
xi) Cabling work on secondary side should also be completed & its
IR valve be ascertained.
same.
xv) The receipt storage and erection should be done as per the
approved FQP.
xvi) The threaded fasteners should be clean & tight and missing or
xvii) It should be ensured that all the times the oil in CT is at the
prescribed procedure.
xix) Any secondary core of CT that is not being put in service should
be short circuited.
i) In order to keep the unit hermetically sealed, the flanged joints with
Nitrogen gas pressure is also not required. If oil level is below the
vi) The CTs are dispatched with secondary terminals short circuited.
used.
Challans, GR etc.
3. After unloading the visual inspection of the packings has been Yes/No
manufacturer.
5. The unpacking of CT has been done carefully to avoid any Yes/No
damage to it.
6. Site where CT is to be erected is ready before the starting of Yes/No
erection work.
7. It has been checked that there is no leakage of oil from CT Yes/No
8. Cranes or other good quality lifting T&P is available at site to Yes/No
arrangement
17. The cable work between C&R panel to marshalling box is Yes/No
complete.
18. Continuity of all cables has been ascertained Yes/No
19. Primary injection test of CT at relay terminal has been Yes/No
circuited.
CHAPTER-10
CAPACITIVE VOLTAGE TRANSFORMER
___________________________________________________________________________
CHAPTER
TEN
___________________________________________________________________________
10.0 Introduction
Back to contents page
reactor plays the role of nullifying the capacitive effect of reactance due to the
i) Capacitor Units
expansion of oil inside the Porcelain. In case of multi-unit stack all the
ii) Transformer
The voltage tapped from the intermediate point of the capacitor is fed
of transformer may be
winding)
3. Total simultaneous burden 300 VA for 0.5 class accuracy
4. Rated output burden and accuracy Winding 1 : 200 VA 3P
over which primary and secondary windings are wound around the
laminations. The insulation between the core and the windings and
level.
forms an integral part with the capacitor unit. In the case of Multi-
ii) Each Capacitor unit has one Name Plate designating the rating of
iii) Bottom-most unit of Multi-Unit stack has one Master Name Plate
fixed on to the Electro-Magnetic Unit and one unit Name plate fixed
10.3 Receiving
Back to contents page
i) That the right CVT has reached at the destination with regard to its
notified immediately.
v) During handling, ensure that the capacitor Unit is always its upright
vertical state.
10.4 Unloading :
Back to contents page
transporting vehicle
iii) Ensure that the Top and Bottom ends of the crates are in order.
iv) Make arrangements for unloading with derricks or cranes and with
v) Unload the crates one by one, taking all precautions required for
fragile material.
vi) As all porcelains are fragile and are susceptible to breakage, avoid
vii) The base unit should be lifted with crane by means of lifting lugs
a porcelain bushing.
viii)For taking the capacitor unit out of packing, use lifting lugs provided
between head & bottom flange until erection and connection are
completed.
10.5 Storage
Back to contents page
(ii) A free capacitive voltage transformer with its terminals not short
injuries to personnel.
vertical position.
iv) When not in use keep the Capacitive Voltage Transformers away
locations.
crate/packing case.
on the CVT.
b) Measurement of capacitance
10.6 Installation
Back to contents page
i) Before proceeding with the installation, keep all the units near
ii) Ensure that the Top, Middle and Bottom units are (if applicable)
name plates.
specified size.
iv) For fixing the base unit, 4 holes are provided on the bottom plate
top flange of the lower unit with the help of studs, nuts and
washers
vi) For assembly of capacitor units which have antifog shads on the
used for coupling have to be first held into the through holes of
the flanges, before the units are placed are above the other.
vii) For handling the base unit & upper capacitor during the erection
viii) The studs used for coupling the capacitor units have to be
10.7 Connection
Back to contents page
independent places
outdoor and earth if CVT is used for carrier coupling otherwise this
terminal is to be earthed.
vi) The cables with large cross sections are inserted through the
vii) The earthing of secondary winding (s) must be done either in the
terminal box at the beginning or at the end of cable but not at the
terminal box.
ix) The quick acting fuses for each secondary windings are mounted in
x) The secondary terminals must not be touched and the head of the
person attending this job should be below the level of the tank
cover.
xi) Only metering winding for monitoring equipment and protecting
connection.
xv) It should be ensured that the jumper is rightly connected to the
to be removed along with the bottom flange from the EMU tank.
ii) After removing the bottom divider from the EMU check for any loose
connection of EMU. This test may be carried out using the shearing
bridge.
iv) In case of any evidence of traces of oil do not energise the CVT.
vi) Apply a very low voltage say 230 V and measure the secondary
vii) Carry out the meggering test on LV terminal of EMU by using 500 V
megger.
i) Oil level in the tank is to be checked. The red line on the oil level
(oil level gauge, cover, oil drainage joints) should be checked for oil
levels.
manufacturer to be contacted.
10.8.2 Defect/Damage
Back to contents page
location of defect .
ii) When the device i.e CVT/CC consists of two or more than two units
iii) The units are calibrated at manufacturer’s works before they are
from the last certificate) on the rating plate and on special plate at
top cover of the upper units. Upper units pertaining to different CVT
iv) Corona shield in two halves are supplied loose in the same packing
unit CVT the unit with single capacitor stack is generally supplied
1/6 of a turn until they are all uniformly tight the maximum torque
being 70 kg-cm.
the insulator If tightening up does not stop the leakage the matter
tightening the nuts slightly. If the leakage does not stop, matter
10.8.4 Erection
Back to contents page
units.
get charged by the electrical fields in the vicinity and they keep
unscrewed.
CHECK FORMAT
10.9 Check Format
Back to contents page
vertical position
2. Physical verification of CVT done as per specifications, Yes/No
supplier/insurance agency.
7. Proper lifting arrangement for different CVT items at site being Yes/No
provided
8. Mounting bolts of base plate have been tightened properly Yes/No
9. Various parts of CVT joined and tightened to the designed Yes/No
torque
10. HF terminal of unutilised CVT is properly earthed Yes/No
11. Care has been taken to avoid short circuiting of CVT Yes/No
secondary winding
12. Crane is used for handling the capacitor units Yes/No
Different
13. erection activities performed as per approved FQP. Yes/No
14. Fuses in CVT marshalling box are OK Yes/No
15. Cable laying activity is complete from relays to marshalling box Yes/No
16. Proper earthing of CVT tank has been done Yes/No
17. Terminals have been properly tightened. Yes/No
CHAPTER-11
POWER LINE CARRIER
COMMUNICATION
___________________________________________________________________________
CHAPTER
ELEVEN
___________________________________________________________________________
11.0 Introduction
Back to contents page
Communication.
between 30 kHZ and 500 kHZ the information wave band is 300 HZ
to 3.4 kHZ.
loss and at the same time de- couple the Communication equipment
The coil is rated to carry full line power frequency current; the
on the station side. These are designed for the following ratings:
Main coil
Tuning Unit
Lightning Arrester.
Corona ring for 400 kV Line Trap (this is generally supplied loose, it
functions.
11.6 Teleprotection
Back to contents page
For high speed protection particularly at 400 kV system the fault should
and then converted into H.F. (higher frequency). Apart from the
signals i.e. (speech, data and Teleoperation) the other signals which
are internally generated i.e. pilot and auxiliary are also converted into
H.F. stage. The pilot is normally used for calling opposite station either
11.8 Earthing
Back to contents page
The last but not the least important is earthing of the PLC terminals and
These excessive current can damage the output stage of the carrier
terminal.
spectrum.
The Power Line Carrier Communication Equipments are basically
i) Line Trap
a) Suspension Mounted
The main Line Trip coil and the Tuning Pot/Lightning Arrester
for hanging from the gantry the Tuning Pot and Lightning
be hung from the gantry with the help of the insulating string and
ball and socket joint. The necessary clamps for hanging the Line
b) Pedestal Mounted
For pedestal mounting, each line trap shall be mounted on a
stool including bolts for fixing the line trap on insulators are of
non-magnetic material.
maintenance/replacement.
The coupling device is suitable for outdoor mounting. All the
wire of specified size with suitable lugs & taped. The impedance
The Coupling Device is earthed through this earth switch during maintenance.
i) Telephone Equipment
power supply point and the Float Charger. The cable length can
Core PVC cable. The cross section of the cable to be used will
will depend upon the layout of the Substation and the position of
battery charger feeds the load and trickle charges the Battery.
b) Co-axial Cable
Co-axial Cable.
connectors.
Till the time the Co-axial Cable ends are not connected to the
time current.
v) General
If the Cabinets are mounted in rows, the distance between the two
Cable.
the cable.
iii) Put the cone and threaded cylinder over the cable
(4/5 inch)
vi) Slightly spring open the split section of the plug interior
vii) Push the cable into the spring opening of the above part
viii)Draw the copper braiding through the two holes in the plug interior
protrudes. (Do not heat the pin too long because of the
polyethylene insulation)
x) Slide the threaded cylinder and the cone back into position and
xii) Fasten the cable beneath the connector plug by means of bracket
allocated for a particular section should not be diverted. This may result
modules to supplier:
iii)It is desired that the cabinet nos. of the PLC terminal should be
duly repaired.
they are found defective, without any efforts to repair them at site.
DO’S DON’TS
&
SPECIAL PRECAUTIONS
11.13 Do’s, Don’ts and Special Precautions
Back to contents page
ASME-IX and all the critical welds should be subject to tests as per
FQP/LOA as applicable.
magnetic material.
vi) Connections of line trap should not foul with any other equipment.
only.
xi) The line traps are packed in wooden crates rectangular in shape
this purpose.
xvi)The body & the internal parts of the line trap should be handled
insulator pedestal.
xviii) While completing the copper connection one should ensure that
erection work.
xx) Before erecting the blocking band of Line Traps are to be checked
protection relay.
cable.
2. All parts have been checked for any physical damage, Yes/No
discrepancy etc.
4. Corona ring for 400 kV WT has been fitted before lifting the same Yes/No
for erection.
10. H.F. point of CVT on which the coupling device is not mounted Yes/No
has been earthed.
11. The remaining, two CVTs have been earthed thro’ coupling Yes/No
device.
12. Conductor take off from line trap has been checked up with the Yes/No
Line Trap Drawings.
13. Connection of Co-axial cable to the cable connector plug has Yes/No
been done carefully as per the specified instructions.
14. About 1m. extra length of Co-axial cable has been provided Yes/No
before cutting.
15. Co-axial cable ends are kept sealed to avoid ingress of moisture Yes/No
till the time these are not connected to the cable connector.
16. All indoor equipments are housed in a well lit/ventilated and dust Yes/No
free room.
17. Proper face to face distance of cabinets inside the PLCC room is Yes/No
maintained between the two rails for maintenance/testing of
equipments.
19. While completing the copper connections it has been ensured Yes/No
that the copper strip connections are properly tinned by
brazing stove and same have been painted to avoid rusting or
oxidation due to moisture.
CHAPTER-12
CABLES
___________________________________________________________________________
CHAPTER
TWELVE
___________________________________________________________________________
CABLES
Back to contents page
12.0 Introduction
Back to contents page
or XLPE. Over the core insulation, a sheath of PVC or plastic PVC tape
i) Conductor
magnetic fields, the control cables should be properly laid and their
They are generally at low voltage (220 V AC, 110 V AC, 22048 V DC,
110 V DC, 48 V DC, etc.). Control cables are wired between the
control panels in the control room, and the various equipments in the
cables are also laid on cable racks inside the cable trenches.
substation 1.1 KV grade power & control cables are procured in full
drum length of 500m +5%. These cable drums are issued to the
drawings.
iii) The drums should be checked with the LOA, GR and MICC for the
at the earliest.
v) Drums after visual inspection should be stored preferably in the
covered area. In case these are stored in open, proper care and
vi) The cable accessories and hume pipes are supplied by the
The cable trench in which the cable is to be buried under the ground
bottom of the trench is levelled, freed from stones and sharp edges of
sand, where the soil conditions are not good. In other cases soft earth
may be used instead of sand. The remaining gap is filled with soft soil
These are used for crossing streets or under railways tracks. The size
earth above.
iv) The length of cable actually required should be more than the
blocks.
v) More length will also help in future to take care of cable faults, when
wastage.
vii) For pulling the cables from drums, rollers are used by placing at
about 2 m spacing.
viii)Power and control cables are secured to the separate cables trays.
The cable trays carrying power trays are on top tiers whereas the
ix) Other cables like coaxial cables are laid separately from power and
control cables.
sealed.
xii) Proper cable tags for identification should be tied to the cable. The
xiii)Concrete or steel pipes that are buried at 1 to 1.2 m level below the
pass through these in case the cable crosses the drains, roads or
rail track.
xiv)All the cable trays, racks & metallic ducts should be grounded by
termination.
iii) Cables are checked for continuity before the termination work.
DO’S DON’TS
&
SPECIAL PRECAUTIONS
12.4 Do’s Don’ts and Special Precautions
Back to contents page
i) Ensure that the cable trench work is complete in all respects and
ii) Ensure that earth flat running is complete and all welding work
that the standard permissible limits for bending are not crossed.
radius of 10x d
i) Each cable and conduit run should be tagged with numbers that
ii) The tags should be of aluminium with the number punched on it and
securely attached to the cable conduit by not less than two turns.
located on both sides of road and drain crossings and also at every
change in direction.
iv) Cable tags should be provided inside the switchgear, motor control
centres, control and relay panels etc. wherever required for cable
gland plate.
v) For drilling of gland plates holes should not be made by gas cutting.
vi) Double compression type nickel plated (coating thickness not less
for all power and control cables to facilitate dust and weather proof
termination.
vii) The cable glands should comprise of heavy duty brass casting,
DG set building and fire fighting pump house should be laid in the
ix) Cable route and joint markers and RCC warning covers should be
xi) Cable racks and supports should be painted after installation with
aluminium paint.
xiii)In the case of equipments located away from cable trench either
trays.
xx) Metal screen and armour of the cable should be bonded to the
drawings/schemes.
the cables.
xxii)All due care should be taken during unreeling, laying and
bends, etc.
up the work and replace all the trench covers after the erection-
actual length and route, testing carried out, termination carried out
should be painted.
of the site. In case any other part of a cable is damaged, the same
possible.
and tied with nylon strap or PVC perforated strap to keep them in
position.
coiled up.
xxxi)Cable entry points should be sealed and made vermin and dust
2. All items have been checked with the packing list, MICC, Yes/No
Challans GR etc.
3. After unloading the visual inspection of the packings has been Yes/No
carried out along with the erection contractor and preferably
with the manufacturer of the equipment.
5. Drums have been checked for quantity and damage to cable. Yes/No
7. Cable has been laid and all civil works performed as per the Yes/No
technical specifications.
10. Cable in cable trenches have been laid as per approved Yes/No
drawings.
11. Length of cable actually required is more than the measured Yes/No
are to take care of cable termination in terminal block and
cable faults in future.
12. Cable laying and termination schedule has been prepared as Yes/No
per the actual site conditions and actual measurements.
13. Cables are being laid as per approved cable laying schedule. Yes/No
14. A cable cutting schedule has been prepared to optimise the Yes/No
cable lengths.
16. Power and control cables are laid on separate cable trays. Yes/No
17. Co-axial cable is laid separately from para & control cable. Yes/No
18. A clearance of 2d (where d= dia of cable) is maintained from Yes/No
centre to centre.
19. Cable ends have been sealed to minimise any damage. Yes/No
20. All cable trays, racks and metallic ducts have been grounded Yes/No
by connecting each to earth/met.
21. Sections of cable trays have been bridged by copper jumpers Yes/No
to retain continuity of earthing.
CHAPTER-13
CONTROL & RELAY PANELS
___________________________________________________________________________
CHAPTER
THIRTEEN
___________________________________________________________________________
13.0 Introduction
Back to contents page
control.
such as faults.
panels, etc. are housed in the control room building of the substation.
The relay and control panels are located mainly in the control room of
Synchronising panels.
ACDB
DCDB
Board for feeding the emergency lighting in and around control room.
i) The panels are free standing, floor (channel) mounting type and
thickness with front sheet and door frames, sides, door, top and
bottom portions.
iii) All doors, removable covers and panels are gasketed all around
v) Panels have base frame with smooth bearing surface which is fixed
vi) Panels are provided with the gland plates at the bottom for cable
entry.
thereon and having wiring access from rear for control panel & either
front or rear for relay panels. In case of panels having width more than
800 mm, double leaf-doors are provided. Doors have handles with
facility.
Duplex panel are walk-in tunnel type comprising of two vertical front
the corridor are provided with double leaf doors with lift off hinges.
Doors have handles with built-in locking or provided with pad-locks
for closing/locking facility. Separate cable entries are provided for the
iv) After unloading the visual inspection of the panels should be carried
out along with the erection contractor and preferably with the
Challans GR etc.
the earliest.
viii)The panels are sent to the erection site or in store if the site is not
these are to be stored for long time. Panels are stored in vertical
position only.
iii) It should be checked that the foundation of the panel is ready in all
v) All the panels are to be checked for alignment, verticality etc. The
i) All equipments on (or in) the panels are mounted and completely
ii) Equipments are mounted such that removal and replacement can
visible.
iii) The centre line of switches, push buttons and indicating lamps are
not less than 750 mm/specified height from the bottom of the panel.
The centre lines of relays, meters and recorders are not less than
iv) The centre lines of switches, push buttons and indicating lamps is
matched to give a neat and uniform appearance. Like wise the top
the panels and between the devices and terminal blocks for the
ii) When panels are arranged to be located adjacent to each other, all
internally.
iii) All the internal wiring is securely supported, neatly arranged, readily
blocks. Wiring gutters & troughs are used for this purpose.
provided near the top of the panels running throughout the entire
v) Wire termination are made with solderless cirmping type and tinned
copper lugs which firmly grip the conductor. Insulated sleeves are
arrangement is adopted.
i) Inside the panels all equipment mounted on front and rear side as
ii) On the top of each panel on front as well as rear side, large and
iii) All front mounted equipments are provided at the rear with
iv) The name plates mounted directly by the side of the respective
v) The name plate ‘inscription’ and size of name plates and letters
i) Plug Point
Panels are provided with a space heater rated for 240V, single
13.11 Earthing
Back to contents page
ii) When several panels are mounted adjoining each other, the earth
this purpose.
iii) Provision is made for extending the earth bus bars to future
iv) Provision is made on each bus bars of the end panels for
vermin proof.
apparent from outside with all exterior surfaces tune & smooth.
v) Ferrules should fit tightly on the wire and not fall off when the wire is
vi) Ferrules in cable should indicate the TB no. of both the ends.
vii) All wires directly connected to trip circuit breaker or device should
panels at site and wires for this purposes should be looped and
erection contractor.
xi) At least 20% spare terminals should be provided on each panel and
blocks.
xii) When semaphore indicators are used for earth switch position they
xiii)Indicating lamp, one for each feeder, for each bus should be
xv) It should be ensured that the erection front is ready for taking up
xvi)Cable entries to the panels should be from the bottom and through
cable glands.
xx) Each switch should bear clear inscription identifying its function.
CHECK FORMAT
13.13 Check Format
Back to contents page
1. All items have been checked with the packing list, MICC, Yes/No
Challans, GR etc.
2. After unloading the visual inspection of the panels has been Yes/No
carried out along with the erection contractor and preferably
with the manufacturer of the panels.
7. The foundation frame has been erected and checked for Yes/No
alignment and level.
8. Panels during erection on frames have been checked for true Yes/No
level by spirit level.
12. Equipments have been mounted for easy removal and Yes/No
replacement.
13. Centre line of switches, push buttons indicating lamps is not Yes/No
at less than the specified height from the bottom of panel.
15. Wire termination are made with solderless crimping type and Yes/No
tinned copper lugs firmly gripping the conductor.
18. Large and bold name plates have been provided for Yes/No
circuit/feeder designation.
20. Proper sized inscription has been done on the name plates Yes/No
21. Each switch has been inscripted clearly identifying its Yes/No
functions.
22. Fluorescent lighting fixtures have been provided for the Yes/No
interior illumination in the panel
23. Heaters have been provided inside the panels to prevent Yes/No
condensation of moisture
24. All metallic cases of relays, instruments and panel mounted Yes/No
equipment have been earthed
___________________________________________________________________
BIBLIOGRAPHY
User’s Manual
Of
Construction
Vol. 3
Soil Investigation Vol. 4 Vol. 3 Vol. 4 Vol. 3 Vol. 4
& Foundation Tower Erection Switchyard Ercn. Of TF, Contracts Budget
Ercn. SR & CB Mgmt. & Finance
Vol. 5 Vol. 5
Stringing Aux. Pkgs.
(Elect.) Vol. 5
Labour
Regulations