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Maintenenace Manual 23.01.17
Maintenenace Manual 23.01.17
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MINIMUM CLEARANCE (IN M) BETWEEN LINES WHEN CROSSING EACH OTHER ... 69
GUARDING SYSTEM .................................................................................................................. 70
1. P.V.C. Guarding: ................................................................................................................. 71
2. Lecing guarding. .................................................................................................................. 72
AT 11 KV LEVEL ............................................................................................................................. 74
DISTRIBUTION TRANSFORMER ............................................................................................. 74
Introduction ................................................................................................................................ 74
Scope: ......................................................................................................................................... 74
Prerequisites: .............................................................................................................................. 74
Checks & Directives: .................................................................................................................. 74
Authorization .............................................................................................................................. 77
Implementation ........................................................................................................................... 78
Review: ....................................................................................................................................... 78
RING MAIN UNIT (RMU) ........................................................................................................... 79
Introduction: ............................................................................................................................... 79
Scope: ......................................................................................................................................... 79
Prerequisites: .............................................................................................................................. 79
Directives & Checks: .................................................................................................................. 79
Tests: ........................................................................................................................................... 81
Maintenance Activity: ................................................................................................................ 82
Authorization .............................................................................................................................. 83
Implementation ........................................................................................................................... 83
Review: ....................................................................................................................................... 83
UNDERGROUND CABLES ......................................................................................................... 84
Introduction ................................................................................................................................ 84
Scope .......................................................................................................................................... 84
Prerequisites................................................................................................................................ 84
Directives & Checks ................................................................................................................... 85
Minimum permissible Bending radius (Table1) ......................................................................... 86
Depth of the cable (Table-3) ....................................................................................................... 87
Current Rating (Table4)- 11 KV XLPE UG Cable .................................................................... 87
Authorization .............................................................................................................................. 88
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Implementation ........................................................................................................................... 88
Review: ....................................................................................................................................... 88
HT OVERHEAD LINES ............................................................................................................... 89
Introduction: ............................................................................................................................... 89
Scope: ......................................................................................................................................... 89
Prerequisites: .............................................................................................................................. 89
Properly Grounding means ......................................................................................................... 89
Clearance .................................................................................................................................... 90
Current carrying capacity of conductor ...................................................................................... 90
Checks & Directives: For 11 KV O/H Feeders ......................................................................... 91
Tests ............................................................................................................................................ 92
Maintenance Activity: ................................................................................................................ 94
Authorization .............................................................................................................................. 95
Implementation ........................................................................................................................... 95
Review: ....................................................................................................................................... 95
Components of an Overhead 11 KV (H.T.) Line of O/H Lines ..................................................... 96
HT AERIAL BUNCHED CABLE .............................................................................................. 101
Introduction .............................................................................................................................. 101
Scope ........................................................................................................................................ 101
Prerequisites.............................................................................................................................. 101
Laying of AB Cables ................................................................................................................ 102
Characteristics of HT ABC....................................................................................................... 102
Symptoms prior to failure ......................................................................................................... 102
Reason of Failure: ..................................................................................................................... 103
Correctives Measures for Installation snags: ............................................................................ 104
Typical Failure of HT AB cable ............................................................................................... 107
Condition Monitoring of Aerial Bunched Cables: ................................................................... 108
Directives & Checks ................................................................................................................. 109
Minimum permissible Bending radius ..................................................................................... 111
Testing of AB cables: ............................................................................................................... 111
Current Rating .......................................................................................................................... 111
Authorization ............................................................................................................................ 112
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Implementation ......................................................................................................................... 112
Review: ..................................................................................................................................... 112
Cable jointing Process .................................................................................................................. 113
Power cables ............................................................................................................................. 113
Functions of Each Component ................................................................................................. 114
Cable Screen – Theory ............................................................................................................. 114
Role of Earthing in Power Distribution ....................................................................................... 118
Introduction .............................................................................................................................. 118
Earthing In Electrical System ................................................................................................... 118
Reason for Poor Earthing Practices: ......................................................................................... 118
Why Earthing Important? ......................................................................................................... 119
Attributes Of Good Earth Connection ...................................................................................... 119
Statutory Requirement of Earthing - IE RULE 1956 ............................................................... 119
Vulnerable Points to Be Earthed .............................................................................................. 120
Terminology ............................................................................................................................. 120
Types of Earth Electrodes......................................................................................................... 121
Types of Earthing ..................................................................................................................... 124
Selection of Earthing System ................................................................................................... 124
Factors Affecting Earth Resistance .......................................................................................... 124
Earth conductor......................................................................................................................... 125
Comparison of conducting materials ........................................................................................ 126
Earthing arrangement for pole mounted sub-station on DP: .................................................... 126
Limits of Earthing Resistance................................................................................................... 128
Range of tolerable current ........................................................................................................ 128
FUSES .......................................................................................................................................... 129
Introduction .............................................................................................................................. 129
Description................................................................................................................................ 129
Fusing factor ............................................................................................................................. 129
Principle of operation ............................................................................................................... 129
Selection of fuse wire ............................................................................................................... 130
Melting points of various metals .............................................................................................. 130
Current Rating of Fuse wire- .................................................................................................... 131
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Autorecloser and Sectionalisers ................................................................................................... 133
Introduction: ............................................................................................................................. 133
Autorecloser: ............................................................................................................................ 133
Sectionaliser: ............................................................................................................................ 133
Scope: ....................................................................................................................................... 133
Prerequisites: ............................................................................................................................ 134
Directives, Checks and Tests: ................................................................................................... 134
Tests: ......................................................................................................................................... 136
Maintenance Activity and check lists: ...................................................................................... 136
Planned Maintenance Activity and check list: ......................................................................... 137
Authorization ............................................................................................................................ 139
Implementation ......................................................................................................................... 139
Review: ..................................................................................................................................... 140
AT LT Voltage Level....................................................................................................................... 141
LT ACB ........................................................................................................................................ 141
Introduction .............................................................................................................................. 141
Receiving and Handling ........................................................................................................... 142
Storing ...................................................................................................................................... 142
Transportation and Installation at site ...................................................................................... 143
Operation .................................................................................................................................. 143
Maintenance and overhauling ................................................................................................... 144
LT UNDERGROUND CABLES ................................................................................................. 146
Introduction .............................................................................................................................. 146
Scope: ....................................................................................................................................... 146
Prerequisites: ............................................................................................................................ 146
Directives & Checks ................................................................................................................. 146
Minimum permissible Bending radius ..................................................................................... 147
Depth of the cable ..................................................................................................................... 147
LT Cables Current Rating......................................................................................................... 148
Authorization ............................................................................................................................ 148
Implementation ......................................................................................................................... 148
Review ...................................................................................................................................... 148
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LT OVERHEAD LINES .............................................................................................................. 149
Introduction .............................................................................................................................. 149
Scope ........................................................................................................................................ 149
Prerequisites: ............................................................................................................................ 149
Current carrying capacity of conductor .................................................................................... 150
Checks & Directives: LV O/H Feeders ................................................................................... 150
Tests .......................................................................................................................................... 154
Maintenance Activity ............................................................................................................... 154
LT ARIAL BUNCHED CABLE (ABC) ..................................................................................... 157
Introduction .............................................................................................................................. 157
Scope ........................................................................................................................................ 157
Prerequisites.............................................................................................................................. 157
Laying of AB Cables ................................................................................................................ 157
Directives & Checks ................................................................................................................. 158
Minimum permissible Bending radius ..................................................................................... 159
Testing of AB cables ................................................................................................................ 159
Current Rating .......................................................................................................................... 160
Authorization ............................................................................................................................ 160
Implementation ......................................................................................................................... 160
Review ...................................................................................................................................... 160
LT METERING & SERVICE CABLE ....................................................................................... 161
Quality Control Checks on Meters and Metering System: ....................................................... 161
LT FEEDER PILLAR .................................................................................................................. 163
Introduction .............................................................................................................................. 163
Precaution ................................................................................................................................. 163
Check List ................................................................................................................................. 164
LT FUSE BOARD ....................................................................................................................... 165
Introduction .............................................................................................................................. 165
Detail of Materials used in above Fuse Board .......................................................................... 165
Melting points of various metals .............................................................................................. 166
Current Rating of Fuse wire ..................................................................................................... 166
DT wise Connecting cable Rating ............................................................................................ 168
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Check List ................................................................................................................................. 168
RECOMMENDATIONS ................................................................................................................. 169
Diagnosis of LD System andRemedial Measures for attending / minimizing Faults ...................... 170
Various Faults / Point of concern with Probable Causes and Remedial Actions ......................... 171
Distribution Transformers ................................................................................................................ 175
Probable Causes of DT failure and Measures .............................................................................. 176
Distribution transformer failure analysis & corrective actions. ................................................... 180
Power Transformers ......................................................................................................................... 205
Probable Causes of Power Transformers failure and Measures ................................................... 206
Best practices at substation level maintenance ............................................................................ 211
DO’s & DON’T’s for Power Transformers ................................................................................. 214
Battery Bank .................................................................................................................................... 218
Probable Causes of DC failure and Measures .............................................................................. 219
Basic defects observed at battery bank ..................................................................................... 219
Over View of Distribution Lines ..................................................................................................... 221
Probable Causes of Underground Cables failure and Measures .................................................. 222
TYPES OF UNDERGROUND CABLE FAULTS ..................................................................... 224
ROOT CAUSE OF FAILURE ..................................................................................................... 225
Overhead Circuits (O/H Lines) ........................................................................................................ 243
Probable Causes of Overhead Lines Faults and Measures ........................................................... 244
Fault in Overhead Lines ............................................................................................................... 246
Corrective & Preventive Action ................................................................................................... 256
Aerial Bunched Cable (ABC) .......................................................................................................... 267
Faulty Joints of Aerial Bunched Cables ....................................................................................... 268
Best Practices for Jointing of AB Cables ..................................................................................... 273
General Tools for Installation of AB Cable ................................................................................. 276
CHECK LISTS/ ANNEXURES ...................................................................................................... 277
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PREFACE
In the modern era and under the pressure of rapid development around the regions, electric utilities
are challenged with a numerous of challenges that include aging infrastructure, enhanced
expectation of reliability, reduced cost, and coping effectively with uncertainties and changing
regulation requirements.
Indeed, for Power Distribution Utility distribution Network represent a complex and critical
physical assets that requires a careful evaluation of their maintenance practices aiming at more cost-
effective tasks.
The first concern of the electric power distribution company is the optimization of the distribution
network maintenance scheduling, to minimize system operating costs and ensure that the system is
running most economically& safely. There is significant pressure on power providers for greater
system reliability and improvement of customer satisfaction, while similar emphasis is placed on
cost reduction. These cost reductions focus on reducing operating and maintenance expenses, and
minimizing investments in new plants and equipment. The optimization of maintenance is one
possible technique to reduce maintenance costs while improving reliability and utilities need to
implement new strategies for more effective maintenance techniques and Asset Management (AM)
methods programs to manage inspections and maintenance activities in order to control HV/MV
substation equipment conditions. However, development of strategies to make sound decisions in
order to effectively improve equipment and system reliability while meeting constraints such as a
maintenance budget is a challenge
Modernizing assets is capital intensive, and for the utilities / industry, regulatory and compliance
requirements many times hinder asset replacement. The business case for early replacement of an
asset with a more modern intelligent version has to be weighed against keeping the old model for a
longer period. This is where the utilities required a more robust maintenance system. Utilities have
progressed from primarily a reactive, break and fix “repair” approach towards a preventive
maintenance approach. Considering the broad array of assets for which utilities are responsible —
Transformers, Circuit Breakers, Ring main units (RMU) and cables — and the risks associated with
asset failure, a reliable maintenance strategy is a priority for the distribution industry. This is the
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primary reason why maintenance systems being developed in power utilities. Some advantages of
maintenance system are more direct, such as getting ahead of equipment failures to hopefully avoid
major breakdowns or outages, or avoiding replacing perfectly good parts when not actually
required. Other benefits come from having a greater understanding of what components are
deployed in the field. The future of asset maintenance is prescriptive, and each step towards this
goal helps companies reduce costs, ensure equipment availability and up-time, increase service
reliability, and most important improve safety.
There is a huge need for the utilities maintenance programs to include rigorous inspection and
assessment procedures – ones that are sometimes quickly being adopted by Predictive asset
maintenance and sometimes by Reliability Centered Maintenance - unfortunately there is a wide
perception exists that offers reaction to failure rather than preventative maintenance. Well-
developed and well-managed maintenance system, designed to prolong and preserve asset lifetime,
are cost-effective if utilities are aware of the current condition of their assets. The right data on
assets is key in deciding where to spend the time & money. An asset life can be extended 10 - 20
years at a cost much lower than the cost of recovering from a critical failure or a new asset.
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DHBVN AT A GLANCE
Bhiwani Bhiwani
Hisar
Hisar
Hisar Zone Fatehabad
Sirsa Sirsa
Jind Jind
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Parameter No. Unit
Districts 11 Nos.
Towns 55 Nos.
Villages 3652 Nos.
Connections-all categories 3017821 Nos.
Distribution transformers installed 243122 Nos.
Capacity of Distribution transformers 11994 MVA
Connected Load 13754 MW
33 kV Substations 273 Nos.
33 KV Line 3261 kM
HT Line (11KV) 70593 kM
LT Line 63842 kM
11 KV O/G Feeders 4374 Nos.
LT / HT Ratio (63842KM / 73854 0.86
KM)
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Page 12 of 333
MAINTENANCE MANAGEMENT
Maintenance Management characterizes the process of leading and directing all or part of an
organization, often a business one, through the deployment and manipulation of resources (i.e.
human, financial, material, intellectual or intangible).
One can also think of management functionally as the action of measuring a quantity on a regular
basis and adjusting an initial plan and the actions taken to reach one's intended goal.
This applies even in situations where planning does not take place. Situational management
may precede and subsume purposive management.
Maintenance management will therefore characterize the process of leading and directing the
maintenance organization.
We can define maintenance management as follows: All the activities of the management that
determine the maintenance.
Objectives or priorities (defined as targets assigned and accepted by the management and
maintenance department), strategies (defined as a management method in order to achieve
maintenance objectives), and responsibilities and implement them by means such as
maintenance planning, maintenance control and supervision, and several improving methods,
including economic aspects in the organization.
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VARIOUS TYPES OF
MAINTENANCE STRATEGIES
Based on Requirement, Resources & Priorities of an Organization for maintenance of any Network
/ System, broadly following maintenance Strategies are being followed:
Reactive Maintenance
Preventive Maintenance
Predictive Maintenance
Reliability Centered Maintenance
Reactive Maintenance
Reactive maintenance (also known as “breakdown maintenance”) is basically the "run it till it
breaks" maintenance mode. No actions or efforts are taken to maintain the equipment, facility, as the
designer originally intended to ensure design life is reached.
In other words Reactive maintenance are repairs that are done when equipment has already broken
down. Reactive maintenance focuses on restoring the equipment to its normal operating condition.
The broken-down equipment is returned to working within service specifications by replacing or
repairing faulty parts and components.
Advantages to reactive maintenance can be viewed as a double-edged sword. If we are dealing with
new equipment, we can expect minimal incidents of failure. If our maintenance program is purely
reactive, we will not expend money on manpower or incur capital cost until something breaks.
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Advantages:
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Disadvantages:
Safety issues
Time consuming
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Inefficient use of resources
Preventive Maintenance
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In other words Preventive maintenance is maintenance that is regularly performed on a piece of
equipment to lessen the likelihood of it failing. Preventative maintenance is performed while the
equipment is still working, so that it does not break down unexpectedly.
The maintenance is scheduled based on a time or usage trigger. A typical example of an asset with a
time based preventative maintenance schedule is an air-conditioner which is serviced every year,
before summer. A typical example of an asset with a usage based preventative maintenance
schedule is a motor-vehicle which might be scheduled for service every 10,000km
Advantages:
Increased component life cycle.
Disadvantages:
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Predictive Maintenance
Predictive maintenance is designed to help determine the condition of in-service equipment in order
to predict when maintenance should be performed. This approach promises cost savings over
routine or time based preventive maintenance, because tasks are performed only when warranted.
Basically, predictive maintenance differs from preventive maintenance by basing maintenance need
on the actual condition of the machine, house, facility, rather than on some pre-set schedule,
preventive maintenance is time-based.
Activities such as changing lubricant are based on time, like calendar time or equipment run time.
For example, most people change the oil in their vehicles- every 3,000 to 5,000 miles
No concern is given to the actual condition and performance capability of the oil. It is changed
because it is time.
This methodology would be analogous to a preventive maintenance task. If, on the other hand, the
operator of the car discounted the vehicle run time and had the oil analyzed at some periodicity to
determine its actual condition and lubrication properties, he/she may be able to extend the oil
change until the vehicle had travelled 10,000 miles. This is the fundamental difference between
predictive maintenance and preventive maintenance, whereby predictive maintenance is used to
define needed maintenance task based on quantified material/equipment condition.
We can optimize the operation of the equipment, saving energy cost and increasing plant reliability.
Advantages:
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Disadvantages:
RCM: "a process used to determine the maintenance requirements of any physical asset in its
operating context.
RCM methodology deals with some key issues not dealt with by other maintenance programs.
It recognizes that all equipment in a facility is not of equal importance to either the process or
facility safety. It recognizes that equipment design and operation differs and that different
equipment will have a higher probability to undergo failures from different degradation
mechanisms than others.
Basically, RCM methodology deals with some key issues not dealt with by other maintenance
programs.
Advantages:
Efficient.
Increased system reliability.
Lowered costs due to no unnecessary maintenance.
Minimized overhauls.
Reduced sudden equipment failures.
Maintenance focused on critical components.
Incorporates root cause analysis.
Disadvantages:
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MAINTENANCE PROCEDURES
INTRODUCTION
Proper maintenance of electrical systems helps in minimizing/preventing unwarranted breakdowns
of Equipment / lines improving the reliability and generating revenue. Periodical or preventive
maintenance is normally followed to keep the equipment continuously in service for desired output.
Condition based maintenance is the most accepted and adopted concept in maintenance now a day’s
which helps in providing advance information about the health of the equipment to take corrective
action in advance.
As the system is growing, it is getting more and more complex. Due to stringent regulations the
utility cannot afford to have breakdowns in the system resulting in interruption of power supply to
the consumer. On the other hand equipment are getting older and are more prone to failure.
Equipment overhaul and major maintenance are also expensive and need to be planned based on the
condition of the equipment rather than on a periodic basis as a routine.
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MAJOR EQUIPMENTS INSTALLED AT 33/11 KV SUBSTATION
1. POWER TRANSFORMER
2. CIRCUIT BREAKER
3. CURRENT TRANSFORMER
4. POTENTIAL TRANSFORMER
5. LIGHTNING (SURGE) ARRESTERS
6. 33 KV LINE ISOLATORS & EARTH SWITCHES
7. BATTERY BANK & BATTERY CHARGERS
8. 11 KV VCB PANELS
9. 33 KV C&R PANELS
10. 33 KV OUT DOOR BUS
11. 11 KV INDOOR BUS
12. APFC PANELS
13. ACDB ( AC-DISTRIBUTION BOARD)
14. ISOLATORS
15. POWER AND CONTROL CABLE
16. CAPACITOR BANK
1. POWER TRANSFORMERS
A transformer is an electrical device that transfers electrical energy between two or more circuits
through electromagnetic induction. Electromagnetic induction produces an electromotive force
within a conductor which is exposed to time varying magnetic. It constitutes the single most
expensive item in a substation.
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Ratings of Power Transformers
S. Alarm /
No. Tripping
4 5 6.3 8 10 12.5
MVA MVA MVA MVA MVA MVA
1
Differential
relay
Pressure
2 Release Valve
(PRV)
Oil
3 Temperature
Alarm (OTA)
Oil
4 Temperature
Trip (OTT)
Winding
5 Temperature
Alarm (WTA)
Winding
6 Temperature
Trip (WTA)
8
Buchholz
Alarm (BA)
9
Buchholz Trip
(BT)
10
Over Current
Relay (O/C)
11
Earth Fault
Relay (E/F)
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In order to provide long and trouble free service, it is important that a careful and regular
supervision and maintenance of the transformer and its components is carried out. The frequency
and extent of such a supervision and maintenance is dependent on the experience, climatic
conditions, environment, service conditions, loading pattern etc. All work done on transformers
should be recorded in maintenance register / checklist.
Alarms &Trippings provided for Power Transformers being used in Sub Stations under
DHBVN
This protection shall be a biased current differential protection & relay should include the following
features:
Vector group compensation.
CT ratio correction.
Biased differential protection.
High-set. Element of suitable setting range
2nd and 5th Harmonic restrains.
Transformer trouble alarm/ Trip e.g. Buchholz / PRD / Winding Temp / Oil Temp etc. shall be
taken as binary inputs in the differential Relay as a common input indicating “Transformer trouble”
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through TMU. However, auxiliary Flag relays/TMU (Transformer monitoring unit) shall be
provided independently for Transformer trouble and trip.
Relay shall be able to display all the Alarms and field status change on the panel at the time of
occurrence and it should be possible to accept the alarms locally from the relay and through the
station controller PC.
A non-directional numerical 3 Phase O/C Protection relay with earth fault unit shall be used as a
backup of Transformer
Non directional O/C (each relay shall have one IDMTLand two high
set definite time relay), 50,51N.
Negative sequence current (unbalance current) 46
Overload relay (49).
Backup relay shall be used for out zone fault of transformer where 11 KV outgoing & 11 KV
incomer feeders don’t tripped.
Note :- Electrically reset type high speed, heavy duty relay shall be used for tripping on
operation of main or b/u protection relays of the Transformer. The two trip coils where ever
provided shall be provided with independent potential free contacts from different fused DC
supplies. Trip relay shall be supervised.
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RESTRICTED EARTH FAULT PROTECTION
Although Biased differential protection provides excellent protection for phase to phase and most
phase to earth winding faults , this element is less sensitive for single phase to earth faults close to
the earth point in solidly grounded transformers. REF takes advantage of the large current in the
neutral conductor to provide sensitive & fast protection for transformer faults close to earth faults.
Basically, an earth fault relay along with external series resistance and a nonlinear resistor
connected as a high impedance forms HI impedance REF protection.
REF protection is so called unit or restricted one as this defined between the two CT’s.
Hence by connecting an REF relay to CT’s installed in correct locations on the Transformer, one
can use REF protection to compliment differential protection in detecting Transformer earth faults.
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General Supervision in 33/11 Power transformer
1. Dirt and Dust: The external transformer surfaces shall be inspected regularly; and when
required cleaned of dust, insects and other air borne dirt etc.
2. Rust and Treatment: A regular inspection is to be done on the external surface of the
transformer tank and radiators.
3. Mechanical Damage: Checks must be carried out for mechanical damage to the fabrications
and associated equipment. Particular attention should be given to vulnerable areas such as
radiators.
4. Check out all Joints for Signs of Leakage: All joints, both welded and gasketted, must be
checked for signs of oil leakage. If there is any doubt of a leak, the area must be cleaned of oil,
using a suitable solvent (methyl alcohol) and sprayed with liquid chalk.
5. Check for Oil Level: All oil levels associated with the equipment including oil conservator
and all oil filled bushings shall be checked. Also the oil in the oil seal should be maintained.
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6. After completing all the checks ensure that all materials or tools, used for maintenance work,
have been removed. All clothes and other debris must be disposed of. The transformer
compound should be left in a clean and tidy condition.
7. Silica Gel Breather: In open breathing transformer, the breather plays active role in
maintaining- the transformer dry by admitting dry air when transformer breathes. In
transformers having air cell or diaphragm, the breather ensures dry air inside the air cell or
above the diaphragm. The silica gel inside the breather becomes pink from bottom to top over a
period of time.
Following test should be carried out before the installation of Power transformer
Polarization index (by Digital Meggar) or Insulation resistance (by Analog meggar)
a) Connect the one lead of meggar at HV side of Transformer and Other one at LV
terminal.
b) Take the IR of 60 Sec and 10 minutes. The ratio of both the results should be greater
than 1 and less than 5.
c) Repeat the same procedure between HV terminal to earth and between LV terminals to
earth.
d) If analog meggar available then just measure the IR of all three condition mentioned
above. It should me 5000MOhm or above for new transformer.
Ratio Test.
a) Connect the ratio meter if available.
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b) Connect the one terminal of meter at HV side other at LV side to confirm the ratio.
c) If ratio meter is not available then just connect the supply of 440V to HV side and
measure the voltage at LV side with respect to the ratio of PTR (33/11 kv). The
deviation should not be more than 0.5 %.
Reference:
Equipment required:
Recommended
S.NO Equipment
Range Accuracy
Transformer winding
1 2 m ohm-2000 ohm +/-0.5%
resistance meter
2 Thermometer 0-50 C +/- 1C
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Testing Procedure:
For calculation of I2R losses in the winding, it is necessary to measure DC resistance of each
winding. The resistance measurement shall be done by circulating the direct current in the winding
and after it has reached a steady state value. In some cases this may take several minutes depending
upon the winding inductance. The time taken can be a reference for hot resistance measurement at
the time of temperature rise test. Temperature of the winding should be stable and for this session,
the test shall be carried out normally before the load loss.
The measurement of winding resistance shall be done using the Transformer ohmmeter. Lead
connection shall be as shown in figure
Inference/Recommendation:
Winding resistance should be less than the guaranteed value (if any). Resistance of each phase
should be nearly equal from highest winding tap to lowest winding tap and same should in
descending order
Cold resistance measurement shall not be made when the temperature is fluctuating rapidly. The
temperature of the windings shall be assumed to be the same as the average temperature of the
insulating liquid and the windings have been under insulating liquid with no excitation and with no
current in the from 3 to 8 hrs.
The current used for measurement shall not exceed 15% of the rated current of the winding whose
resistance is to be measured.
Polarity of the core magnetization shall be kept constant during all resistance readings.
Reading shall be taken only after attainting the steady state values.
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The voltmeter leads shall be independent of the current leads and shall be connected as close as
possible to the winding terminals tightly.
Frequency: Winding resistance test should be done half yearly basis/ routine maintenance/major
overhauling /emergency condition/ breakdown
Scope:
Equipment required:
Recommended
S.NO Equipment
Range Accuracy
Testing Procedure
Remove the Neutral Earth Link of the transformer. The transformer should not be
connected to the system earthing.
Ensure the terminals are properly cleaned & current terminal is clamped properly.
Check the TTR set & earth it properly
Tap changer to be operated (over its entire range, mechanically or electrically) at least
once prior to the test.
Arrange the circuit as per diagram & Set the voltage ratio on the equipment (6:1 OR 3:1)
as per testing equipment.
Take the reading (ratio) with every tap (from tap 1 to tap 17). Compare it with standard
result as per name plate specification
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Schematic Drawing
Confirmation of Test
If the result fulfilled the basic transformation equation N1/N2=V1/V2. With increasing the tap
from 1 to 17. The voltage change from -5 to +15 times respectively of the rated valve of the
primary side. Maximum Deviation +/- 2 % between different phases at same tap is accepted only.
Inference/Recommendation
Turn ratio is recommended during commissioning, tap changer replacement & after the major
overhaul of the transformer
While measuring the voltage supply at various terminals, supply voltage at HV terminal should not
be very high.
Frequency: Transformer turn ratio test should be done half yearly basis / routine maintenance /
major overhauling / emergency condition / breakdown
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CAPACITANCE AND TAN DELTA
Scope
Equipment required
Recommended
S.NO Equipment
Range Accuracy
1 TAN DELTA 1 KV -11 KV 0.003 %
Testing Procedure
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Perform the test as follows
Ckt. Description
Test ID Line Configuration KV
B-Ref to 10 KV GND
a. CH+CHL RB 2 or 10
……………
b. CH …… GAR RB ………
……………
c. CHL ….... ………. ………
Schematic Drawing
we measure capacitance and tan delta with Ch&Chl in parallel. In GST + Guard mode –
Cl is shorted and the measurement of Chl is not taken. We only measure Ch value.
In UST mode – the grounded portion: Ch&Cl is not measured and we only measure Chl.
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Confirmation of Test
Capacitance
If the sum of CH (l –guard) and CHL (in UST mode) is equal to CH+CHL provided the results are
taken on the same scale of reference then the capacitance value is confirmed.
The value of tan delta should be ideally within 1% . Although a tolerance limit of - 100% to
+100% can be allowed for older transformers.
Inference/Recommendation:
The di-electric loss of any insulating material is given by V2 C ω tanδ. If the dielectric loss is more
than the di-electric strength of the insulation would be reduced. In the ideal case the capacitive
current leads the voltage by 90 degree. But in practice, in all insulating system, there exists a loss
current Ir which is small in magnitude but in phase with the voltage. The total current I therefore
lead the voltage by an angle less than 90 degree. The angle by which it is less than 90 degree is also
known as loss angle delta. The test kit measures voltage current and power and with these
measurements the insulation power factor is determined. For a well processed insulation system, the
di-electric loss is low with a correspondingly low loss angle. When the loss angle is small then
cosØ is nearly equal to tanδ.
If the value of tan delta is more than the limit specified above then the subject transformer is kept
under observation. Higher value of tan delta indicates presence of moisture in the transformer. The
same test is performed again after 2 months and if the results deteriorate the following actions are
recommended.
I. DGA analysis
If the test results still do not improve then the transformer needs to be internally inspected or to be
sent for repair.
Tan delta test is the test give the complete information about the insulation; it should be
performed on the transformer on the routine basis.
Transformer should be discharged after completion of the test.
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Scope
Reference
Equipment required
Recommended
S.NO Equipment
Make Range Accuracy
1 IR tester Megger Up to 10 T +/-3
Testing Procedure
Confirm that equipment under test is de-energized & no parallel circuits are connected
to the equipment under test. In the case of neutral grounded equipment
(transformer/motor/generator) ensure that the ground connection to neutral is removed.
Equipment terminals should have adequate clearance. Connecting leads shall be
properly insulated and as short as possible.
In case transformer neutral star connection is opened and each phase winding shorted
and grounded.
Connect the winding under test to 'L' terminal of the megger Connect 'E' terminal of
megger to Ground.
In case of the digital battery operated megger set the test voltage and time before staring
the test.
Apply the suitable voltage for 1 minute & repeat the test 2-5 times to get more accurate
value.
Total DC current IDC seen by the current coil of the megger in insulation resistance measurement
has the following four components.
IDC = IC+IA+I1C+I1S
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IA = Absorption current of the insulation
I1C = Conduction leakage current through the insulation
I1S = Surface leakage current
At beginning IC and IA components of current flow for several seconds or minutes depend upon the
size of the insulation, Magnitudes of these two components become zero after that. Remaining two
components of the current remain constant for a given applied voltage and are true indicator of
insulation condition.
Absorption index = (IR value after 60 seconds) / (IR value after 15 seconds) Polarization index =
(IR value after 600 seconds) / (IR value after 60 seconds)
Schematic Drawing
Confirmation of Test
IR test is routine test of the switchgear while Polarization Index tests of switchgear conduct during
commissioning, overhaul and maintenance to get the condition of the insulation. Limit level of the
tests.
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Inference/Recommendation:
IR test is recommended after breakdown, overhauling & maintenance to get the condition of the
insulation while the PI test is conducted during commissioning or major overhaul of the equipment.
If the results satisfy the basic limits or the specification by the vendor then equipment is
recommended healthy for charging.
Temperature difference between oil and ambient should not be greater than 2o C
After completing the test all the terminal of the test object should be earthed for
significant time to allow any charge to negligible value.
All metal part and bushing should be cleaned
IR test is to be done before and after all the routine tests
Frequency: Tan delta & capacitance test should be done half yearly basis / routine maintenance /
major overhauling / emergency condition / breakdown
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Dissolved gas Analysis (DGA)
Dissolved gas analysis is the study of dissolved gasses in transformer oil.
The gasses produce due to
Oxidation
Vaporization
Decomposition
During normal transformer operation, gasses are produced. But when there is a fault, the gasses are
produced in larger quantities. The gasses produced are proportional to the fault.
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2. CIRCUIT BREAKERS:
At 33 KV level
1. Oil circuit Breakers
2. Vacuum circuit breaker
At 11 KV level
It is the rms. Value of the ac component of the fault current that the circuit breaker is capable of
breaking under specified conditions of recovery voltage.
It is the rms value of the total current comprising of both ac and dc components of the fault current
that the circuit breaker can break under specified conditions of recovery voltage.
The rated making current is defined as the peak value of the current (including the dc component) in
the first cycle at which a circuit breaker can be closed onto a short circuit.
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current, both a.c. and d.c. components) of the current that the circuit breaker can carry safely for a
specified short period.
BREAKER TIMING
CONTACT RESISTANCE MEASUREMENT
BREAKER TIMING
Scope:
Reference:
IS-14658:1999 IEC-62335
IS/IEC-60947
Equipment Used:
Recommended
S.NO Equipment Range Accuracy
1 SCOT MXP 0.1 Volt-1000 Volt 0.01%
Testing Procedure:
Page 41 of 333
Schematic Drawing:
Confirmation of Test:
Breaker opening time should be less than the closing time of the breaker, it should
come in the range of 30-45 ms. while closing time should be 40-60 ms.
CO- time breaker should at the middle of the closing and opening time.
Opening time < closing -Opening time < closing time
Please refer GTP Details of the Breaker for confirmation of the Timing Results.
Inference/Recommendation:
If the specimen breaker satisfies the respective condition then the respective breaker is considered
to be satisfactory. If any deviation is observed from above mentioned condition then corrective
action should be taken with the help of the manufacturer /OEM.
Scope:
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Reference:
IS-14658:1999 IEC-62335
Equipment Used:
Testing Procedure:
Schematic Drawing:
Confirmation of Test:
Inference/Recommendation:
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** Breaker /Isolator maintenance /repair is recommended if the variation is 50 % isobserved
w.r.t commissioning results.
3. CURRENT TRANSFORMERS:
Principle
The current transformer works on the principle of variable flux. In the "ideal" current transformer,
secondary current would be exactly equal (when multiplied by the turn’s ratio) and opposite of the
primary current
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Design
There are two basic types of current transformers: wound and toroidal. Wound current transformers
consist of an integral primary winding that is inserted in series with the conductor that carries the
measured current. Toroidal or donut-shaped current transformers do not contain a primary winding.
Instead, the wire that carries the current is threaded through a window in the toroidal transformer.
The most common design of CT consists of a length of wire wrapped many times around a silicon
steel ring passed over the circuit being measured. The CT's primary circuit therefore consists of a
single 'turn' of conductor, with a secondary of many hundreds of turns.
Common secondary’s are 1 or 5 amperes. For example, a 400:5 CT would provide an output current
of 5 amperes when the primary was passing 400 amperes. Typically, the secondary connection
points are labeled as 1s1, 1s2, 2s1, 2s2 and so on, or in the IEEE standard areas, X1...X5, Y1...Y5,
and so on. The multi ratio CTs are typically used for current matching in current differential
protective relaying applications.
C T MANGETISING CHARACTERISTICS:
The working range of a protective CT extends over the full range between the ankle and the knee
points and beyond, whereas the measuring CT usually operates in the region of the ankle point.
The major difference in requirement between those for metering and those for protection is that
with the former, specified accuracies are essential over a range of primary current about 5% full
load Upto 125%. Whereas the protective purposes, we are concerned with accurate secondary
reproductions of the primary currents from about full load upto those of short circuit magnitude, the
latter being many times full load. It is therefore a primary requirement, that protective CTs should
have a high saturation level. Whereas those for metering should preferably saturate at low level,
thus protecting the connected instruments or meters against over currents.
The point at which a CT begins to saturate is known as the knee point on the curve of its
magnetizing characteristic and is by definition, the point where the exciting current increases by
50% for a 10% increase in secondary voltage typically as shown in figure.
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10% Increase in
secondary voltage
SECONDARY VOLTAGE
KNEE
POINT
50% Increase in
exciting current
POLARITY TEST
KNEE POINT TEST
INSULATION RESISTANCE OF CURRENT TRANSFORMER
POLARITY TEST
Scope:
To measure ratio of current transformer; potential transformer.
Reference:
Recommended
S.NO Equipment
Range Accuracy
1 DC source ( 1.5 to 6 V Dry Cell-1 or 2 ) 1.5 Volt-6 Volt
2 Multimeter 0.02 volt -1000 volt 0.003
Testing Procedure:
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Connect as per the diagram. In the case of tapped secondary windings, the full winding
to be considered.
Close the switch momentarily (for a second) and open. Observe the deflection of the
meter and note whether it is positive or negative.
If it shows positive value for the given connection, then the marked polarities are
correct. Marked polarities can be concluded incorrect if it shows a negative value
Schematic Drawing
Confirmation of Test:
If the meter show positive valve then the polarity of the CT is appropriate if meter
shows any negative valve then few corrective action can be taken out
If the test is carried out on the terminals of the CT junction box, repeat the test on the
direct CT terminals after the disconnection of associated wiring. If the marked
polarities are correct at the CT terminals, then the associated wiring up to the junction
box to be rectified and repeat the test after rectification.
If the marked polarities are wrong at the CT terminals, reject the CT and inform the
concerned Maintenance Engineer for necessary rectification.
Repeat the test after the rectification
Inference/Recommendation:
If the specimen breaker satisfies the respective condition then the respective breaker is considered
to be satisfactory. If any deviation is observed from above mentioned condition then corrective
action should be taken with the help of the manufacturer or vendor.
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Dos and Don’ts:
Contact should be cleaned properly before testing. Battery source of proper value should be used.
Scope:
The main purpose of knee point voltage is to identify the core saturation characteristics.
Reference:
1EC60044-1 2003-02
IS 2705
Equipment Used:
Schematic Drawing:
Testing Procedure:
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Confirmation of Test:
On applying the voltage at current should increase in the same proportion. If current
increases 50 % on increase the voltage by 10% that it is considered Knee point of the
CT’s core.
Generally Knee point voltage of CT cores is as below
Inference/Recommendation:
Measurement of knee point voltage is very essential for both metering and protection. Higher knee
point voltage of meter core CT could cause of burning of meter in the same way low knee point
voltage in protection would cause of unwanted tripping.
Scope
To ensure proper dryness of all active parts of current transformer. To ensure clearance between
windings and earth.
Reference
Equipment required
Recommended
S.NO Equipment
Range Accuracy
1 IR tester Up to 10 T +/-3
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Testing Procedure:
Confirmation of Test
Inference/Recommendation:
IR test is recommended after breakdown, overhauling & maintenance to get the condition of the
insulation. If the results satisfy the basic limits or the specification by the vendor then equipment is
recommended healthy for charging.
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After completing the test all the terminal of the test object should be earthed for
significant time to allow any charge to negligible value.
IR test is to be done before and after all the maintenance.
Visual Inspection: Current transformers are normally filled with oil and have oil impregnated
paper insulation for both primary and secondary winding. Careful inspection is to be made for any
trace of oil leakages. Oil leakages are more prone through cemented joints or secondary terminal
box due to improper sealing of terminal studs.
Visual inspection is also to be carried out on the healthiness of terminal connections, condition of
porcelain, development of cracks, chippings, cleanliness of insulator surface etc.
Secondary Terminals Connections: Stud type terminals are preferred in Marshaling box cable
terminals. This gives better grip even if more than one wire is connected to one terminal. But pin
type terminals are also provided in some cases. Since wires may get loose due to vibration, climatic
condition, it is required to check tightness of terminals periodically to avoid mal-operation/ non
operation due to improper contacts. All terminals of unused CT secondary terminals are to be
properly shorted to avoid development of abnormal voltage and subsequent failure of CTs in case
they are left open. The tan∂ test tap is to be properly earthed to avoid damage to insulation.
Primary Terminals: Thermo vision scanning indicates proper connection of primary terminal. If
thermo vision is not carried out, physical checking of terminal connection is to be done with proper
torque. As CT primary carries heavy current, any loose joint may lead to arcing and welding of
terminal connectors.
In industrial areas where pollution levels are high, due to saline atmosphere/ chemical
contamination, porcelain insulators of electrical equipment shall have higher creepages.
4. POTENTIAL TRANSFORMERS
Voltage transformers (VT) or potential transformers (PT) are another type of instrument
transformer, used for metering and protection in high-voltage circuits. Typically the secondary of a
voltage transformer is rated for 110 V at rated primary voltage, to match the input ratings of
protective relays.
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Testing of potential transformer
RATIO TEST
Scope:
To ensure voltage ratio of test on PT / CVT.
Reference:
IEC 60044-1
IEEE C57.13 standard requirements for instrument transformers
Equipment Used:
Recommended
S.NO Equipment
Range Accuracy
1 1Ø variac 0-260 V +/-3
2 Voltmeter 650 V +/-2
Testing Procedure:
Make the connections as in drawing for PT. Ensure the secondary cores are kept open circuited.
Switch on the supply and gradually increase voltage up to 200 V (VP) Record corresponding
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secondary voltage (VS) on all available cores. Compute actual Ratio =VP/VS and compare that
with expected values. Compute the deviation for all cores. Repeat the test on PTs on other phases.
Schematic Drawing:
Confirmation of Test:
Ratio test is a routine test of the potential transformer, ratio test is recommended during
overhaul and maintenance to check the expected ratio of potential transformer. Limit
level of the tests is +- 3 %.
Inference / Recommendation:
Measurement of ratio test is very essential for potential transformer. Error in ratio test has
significant effect on metering and protection circuit. It is recommending that ratio error in
potential transformer shall be in the limit during every checkup.
CHECK LIST FOR MAINTENANCE OF POTENTIAL TRANSFORMERS-
ANNEXURE-PT / MAIN / 01
Lightning is one of the most serious causes of over voltage. A lightning rod provides a
cone of protection, which has a ground radius approximately, equal to its height above
the ground. The typical lightning arrester also known as surge arrester has a high voltage
terminal and a ground terminal.
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LA voltage rating Corresponding to the system voltage
ARRESTER RATING IN
RATED SYSTEM HIGHEST SYSTEM
KV FOR EFFECTIVE
VOLTAGE (KV) VOLTAGE (KV)
EARTHED SYSTEM
11 12 9
33 36 30
66 72.5 60
Surge Arrestors installed in the substation are intended to divert surges to earth and thus protect
costly switchyard equipment. Proper insulation coordination is necessary for enhancing life span of
costly substation equipment.
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Surge Arrestors are monitored basically using three tests to evaluate their condition. Leakage
current monitoring, Insulation resistance measurement and thermo vision scanning would indicate
any deterioration in surge arresters. Out of these, leakage current measurement and thermo-vision
scanning are on-line measurement and shut down is required for IR measurement. As system
availability is crucial for utilities, more emphasis is to be given for on-line measurements.
As per IEC-60099(5), the following condition monitoring techniques for the surge arresters in
service are suggested:
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6.
Disconnectors have main current carrying arms and operating mechanism for connection and
disconnection. Being off-line devices, they are normally air break type. Normally horizontal double
break, Horizontal center break, Pantograph, Vertical break Disconnectors are in use in EHV
substations.
The alignment of Disconnectors is very important for smooth operation. The limit switches, the
healthiness of auxiliary contacts needs to be checked periodically. The main contacts are to be
inspected and made smooth if any pitting marks seen. All moving parts are to be lubricated for
smooth operation. The gear mechanism and motor normally do not require any maintenance and
manufacturer's' recommendation should be referred for maintenance of gears.
Earth Switches:
The earth switch is a safety device and smooth operation is to be ensured by proper alignment. The
earth blade contacts are to be cleaned properly for proper contact and contact resistance to be
measured to ensure healthiness. The earth connection from blade to earth is to be carefully checked.
All the joints should be tightened. Flexible copper braid connections are provided and healthiness
ensured. All moving parts should be lubricated for smooth operation.
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7. BATTERY AND BATTERY CHARGERS:
In substation DC supply has equal importance. All protection & indication circuits enable with DC
supply only. Substations generally use Lead Acid batteries / Nickel-Cadmium batteries for DC
supply. Now a days valve regulated lead acid batteries (maintenance free batteries) are also in use
for substation applications.
Cell containers are to be kept always clean to avoid surface leakage. Any leakage is to be attended
immediately. Vaseline J white petroleum jelly is to be applied on battery terminal and inter-cell
connectors, nuts and bolts to avoid sulphate deposit. The rubber seal at the base of the terminals and
on cell lid is to be fitted properly and to be replaced if damaged. All connections are to be checked
for tightness.
Battery Chargers:
Battery charger is to be maintained for keeping the battery always charged and also to supply
normal DC load for operation.
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Initial Requirements:
The following list gives the initial requirements for all battery capacity tests
Check all battery connections and ensure that all connections are proper and clean.
Record the specific gravity and float voltage of each cell just prior to the test.
Record the electrolyte temperature of 10% or more of the cells to establish an average
temperature.
Record the battery terminal float voltage.
Take adequate precautions (such as isolating the battery to be tested from other
batteries and critical loads) to ensure that a failure will not jeopardize other systems or
equipment.
Discharge Test: The ampere-hour capacity of a battery varies with the rate of discharge. The
capacity is more at slower rates of discharge and less at higher rate of discharge. The Indian
Standards adopt 10 hr. rate as the standard rate of discharge for specifying the AH capacity of
stationary batteries.
Disconnect the charging source, connect the load bank to the battery, start the timing,
and continue to maintain the selected discharge rate.
Maintain the discharge rate until the battery terminal voltage decreases to a value equal
to the minimum average voltage per cell as specified by the design of the installation
(e.g. 1.75 V) times the number of cells.
Read and record the individual cell voltages and the battery terminal voltage. The
readings should be taken while the load is applied at the beginning of the test, at
specified intervals, and at the completion of the test. The readings are to be taken on
hourly basis.
If one or more cells is approaching reversal of its polarity (+ 1 V or less) and the test
nears the 90-95% expected completion time, continue the test until the specified
terminal voltage is reached.
If earlier in the test an individual cell is approaching reversal of its polarity (+ 1 V or
less) but the terminal voltage has not yet reached its test limit, the test should be
stopped, and the weak cell should be disconnected from the battery string and bypassed
with a jumper of adequate conductor capacity. The new minimum terminal voltage
should be determined based on the remaining cells. The test should then be continued in
order to determine the capacity of the remaining cells. The time required disconnecting
the cell, installing the jumper and restart the test shall not exceed 10% of the total test
duration or 6 min, whichever is shorter. This "downtime" shall not be included in the
test discharge period (i.e., the capacity determination shall be based on the actual test
time).
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8. 11 KV VCB CONTROL AND RELAY PANELS
A circuit breaker is an automatically-operated electrical switch designed to protect an electrical
circuit from damage caused by faults. Circuit breaker can be reset (either manually or
automatically) to resume normal operation.
OPERATING PRINCIPLE
Under fault conditions, current intensity increases multiple times the normal current flow. This
current senses by relay and energized tripping coil of breaker to isolate the system. Circuit breaker
also used to isolate the section manually
11 KV bus and outgoing 11KV outgoing feeders supply voltage to field via VCB circuit breakers
connected with 11KV bus. Control panels are basically the monitoring & operation unit in a grid
substation. It is used for operation & monitoring purposes.
Following activates shall be monitored at C&R panels
CB ON
CB OFF
Spring Charge
L/R Switch Position on C&R Panel
Protection Operated by Trial Tripping from Relay
Common trip circuit healthy logic
Trip Circuit Healthy
Trip Circuit Healthy for 86
DC /AC Failure Indication, operating of DC fail relay (80)
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9. 33 KV CONTROL & RELAY PANELS
33 KV relay & control panels are used to operate 33 KV outdoor circuit breakers. It also used to get
all the monitoring information like breaker on /off status, spring charge, local remote status, trip
circuit healthy information, DC & AC voltage related information etc.
33 KV control panels also include relays for protection & master trip relays also.
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10. 33 KV OUT DOOR BUS
33 KV outdoor bus is used to connect incoming lines, power transformers, and outgoing lines etc.
33 KV outdoor bus works as the most visual architecture of a grid substation to interconnect various
substation equipment.
The size of the bus-bar is important in determining the maximum amount of current that can be
safely carried. The bus-bar should be able to carry the expected maximum load current without
exceeding the temperature limit. The capacity of bus should also be checked for maximum
temperature under short circuit conditions. Different types of bus-bars, are used in a substation in
accordance with the safety and reliability considerations.
APFC consists of a number of capacitors that are switched by means of contactors. These
contactors are controlled by a controller that measures power factor in an electrical network.
Depending on the load and power factor of the network, the power factor controller will switch the
necessary blocks of capacitors in steps to make sure the power factor a selected value. Power factor
reduce due to high inductive load in system. Presence of this high inductive load power factor
reduces.
Generally on any supply system power demand is varying, power factor also varies as a function of
load requirement. Hence it is difficult to maintain consistent power factor by using fixed
compensation i.e. fixed capacitors. Thus under light load condition it may cause leading power
factor, which results over voltage, Saturation of transformer, Mal-operation of relays, Penalty by
electrical authority .
CHECK LIST FOR APFC CONTROLLERS -
ANNEXURE-11 KV APFC /MAIN/01
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13. ACDB (AC-DISTRIBUTION BOARD):-
AC supply is required at grid substation for various purpose. It includes.
Supply to ac motor of breakers.
Charging of battery banks
Switch yard lighting system.
Panel lighting system.
Sources of supply for grid auxiliaries.
Normally a local transformer is used for such type of supply. Also a temporary sources also
available at grid level to supply in case of maintenance of local transformer.
An earthing system in a sub-station is to provide under and around the sub-station a surface which
shall be at a uniform potential and near zero or absolute earth potential as possible .This provision
ensures that no human being in sub-station is subjected to a shock or injury on occurrence of a short
circuit or development of other abnormal conditions in the equipment
Installed in the yard.
Ground mat is provided below ground level. Earth electrodes are driven into ground at several
points and are connected to grounding mat to form earth mesh. All the structures, Transformers &
other power equipment are connected to this mesh by galvanized steel strips (40x5 mm).
Earth Electrodes is a metal plate, pipe or a conductor electrically connected to earth. Copper,
Aluminum, mild steel, galvanized iron are generally used for electrodes.
Generally 40mm dia, 2.6m long GI/MS rods are used
EARTH MAT:
It is formed by steel 75/8 flats laid horizontally at a depth of 0.5 m below surface of ground to form
a mesh of rectangular formation & are welded together. The spacing of earth rods is determined by
required touch & step potential. In addition to earth mat, earth electrodes are used these are also
connected to the mesh. Solid bar risers are welded to mesh and brought up near the equipment
foundations.
BASIS FOR DESIGN OF GROUNDING SYSTEM
Magnitude of fault current
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Transient Over voltage
Lightning Protection
Application of Protective devices for selective ground fault protection
Type of load served viz. Motor, Generator etc.
GENERAL GUIDELINES FOR EARTHING
An effective grounding system must satisfy the following conditions:
Provide a low impedance path to ground for personnel and equipment safety.
Withstand and dissipate repeated faults and surge currents
Provide ample corrosion allowance to various chemicals to ensure continuous service during
life of the equipment being protected.
Provide rugged mechanical properties for easy driving of earth electrodes with minimum
difficulty.
All non-current carrying metal parts associated with installation shall be effectively earthed
to a grounding system or mat which will limit the touch and step potential to tolerable
values.
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Shock duration
Material of earthing mat conductor
Earthing mat geometry
Copper – Mostly used for grounding as it is less prone to corrosion and has better
conductivity.
Effect of Moisture
Moisture has a great influence on resistivity value. Resistance drops quickly to minimum steady
value at 15% moisture. After that it has a little affect.
Effect of Temperature
Soil resistivity decrease sharply with decrease in temperature below 0 OC. It signifies need of
burying electrodes deep.
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Increasing size of driven rod.
Soil treatment with salts. These are effective up to the soil of resistivity 300 ohm
meters. After that other methods are used. One of the most suitable substance for
chemical treatment of soil of very high resistivity for reducing the earth resistance is
Natural Clay, also called Bentonite. It is non corrosive, stable & has a resistivity of 2
Ohm.m at 300% moisture.
ANNEXURE-EARTHING/MAIN/01
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33 KV Transmission lines
In DHBVN, HVPNL is the main source of supply, all 33 KV lines come to substations via rail or
RCC pole structure.
Following conductors have been used
RATED CURRENT
CONDUCTOR MVA LOADING (33 KV
S. NO. AREA UNDER NORMAL
TYPE LEVEL)
CONDITION
Page 66 of 333
Stay Sets 8' long complete with X-Plat 460mm of Angle 65x65x6 Elbow & rod with
Disc
Stay wire 7/8 SWG
G.I. Pipe 40 mm dia 6 mtr. Long for earthing
Earthing with Earth rod as per Drawing
GSL 8 SWG
MS Nuts & Bolts
Danger Plates (Enameled)
Number Plates (Enameled)
Phase plate for each phase set of 3 (on each H-Pole & 4-Pole)
Eye Screw Bolts 9”x5/8"
Barbed Wire
"G.I. Strip 25x6 mm 9 meter. For earthling
Knee Bracing - MS Flat 50x6
Catenary wire 7/14 SWG
CI pipe 250 mm diameter 14 mm thick for highway crossing
S/C 630mm2 33kV XLPE cable
End termination kit for S/C 630 sq. mm Cable
33KV Isolators (630 Amps), with clamps
ACSR Conductor 150mm2 (Leopard)
33 KV AB cable 3 Core 185+240 mm2
End termination kit for AB cable 3 Core 185+240 mm2
Dead end calm p assembly with eye hook
Trench (with angle and MS sheet cover) for laying 33 KV XLPE cable in yard
Non Directional (50/51 & 50N/51N) OR Directional O/C and E/F (each element shall
have one IDMTL and three high set definite time relay) (67 R, Y, B and 67N)
Negative sequence current (unbalance current) (46)
Overload relay (49).
VT supervision relay and Trip circuit supervision relay.
Integrated CB failure protection.
Configurable LEDs shall also be provided to indicate the relay operation and the alarm
/ status change of a bay equipment e.g. Phase Fault operated / Earth Fault operated/CB
open / CB close / spring charge etc.
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Electrically reset type high speed, heavy duty relay shall be used for tripping on operation of
main protection relays of the Line. The two trip coils where ever provided shall be provided with
independent potential free contacts from different fused DC supplies .Trip relay shall be
supervised
MAINTENANCE OF 33 KV LINES
Normal ground patrolling of lines should be conducted by lines maintenance crew periodically.
Periodicity will be decided on the basis of importance of the line, terrain condition, and proximity
of the line to habitations, forests, gardens, water borne areas etc. and environmental impact on the
line.
During ground patrolling of the line, the patrolman should check for the following
Special patrolling of the line should be done after momentary tripping of the line on fault, for any
defects. Defects noticed shall be rectified immediately if this can be attended while the line is live
or at the earliest by availing shutdown, anyway, before the defect develops into a major one causing
breakdown. Proper planning of materials and manpower is required in order to carryout rectification
under shutdown in minimum time to avoid/minimize interruption to loads.
Break down maintenance: When a permanent/semi-permanent fault occurs on the line, the line
may break down causing interruption of longer duration. The faults could be snapping of
conductors, disconnection of jumpers, cross-arms/ pole twisting or pole collapse with or without
damage to foundation. This may be due to various reasons like heavy wind due to storms,
weakening of pole due to aging, accidents, thefts etc.
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Various condition monitoring methods are:
-- IR measurement of insulators
-- Contact resistance measurement
Page 69 of 333
CHECK LIST FOR MAINTENANCE OF 33 KV LINES
ANNEXURE-33 KV LINES /MAIN/01
GUARDING SYSTEM
Guarding means safe guard. This is below the line. In case of conductor snapping, it will touch the
guarding wire before laying on ground or will lay on guarding. The guarding is always earthed. The
line protection will operate and will switch off the line. Snapped conductor will not remain charged.
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In absence of guarding, conductor will fall on ground and as no protection is operated, conductor
will remain charged. This will cause accidents. Hence the guarding is very essential.
Types of Guarding:-
P. V. C. Guarding.
Lecing guarding.
1. P.V.C. Guarding:
This is mainly used for L. T. Lines passing through agriculture field. This is used where formation
of line is vertical. The upper end is tied in shackle bolt and lower end is tied to the neutral. A G.I.
wire frame is prepared so that there will be horizontal G.I. wire piece at equal distance below every
conductor. The vertical wires of the frame are insulated with P.V.C. pipe. Even conductor swings, it
will not be earthed due to P.V.C. pipe. In case of snapping of conductor, it will make contact with
the G.I. wire and get earthed, resulting blowing of the fuse.
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2. Lecing guarding.
This has following types. a) Carpet guarding, b) Cradle type c) Box type. There is two, three or four
guard wire for lacing guarding. These are bound with cross arm. The horizontal laces at a specific
distance are tied up to the above wires. This guarding is used up to 33 KV lines
Carpet Guarding: - The specific length cross arms are fixed on the poles. Four G.I. wires are used
for guard wire. Lacings are tied up at specific distance. This type is used for power line crossing or
power and telephone line crossing.
Cradle Guarding: - It consists of 6 guard wire. Four are on lower side and two on the upper side.
Cross lacing is done from three sides. It is also called Tray guarding. Even though the conductor
while snapping jumps up drastically, it will not go out of the cradle guarding. This is used for
railway or L.T. to 33 KV guarding in residential area, for road crossing or along the road lines.
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Box type guarding: - This is used for composite lines. By fixing cross arms to the lower line,
carpet guarding is done and also for the upper line, the upper guard wire is fixed to the lower by
vertical lecing.
Road crossing and guarding.
As far as possible, road crossing should be at right angle, but not less than an angle
of 60 degrees.
Cradle guarding is used for road crossing of power line or along the line.
G.I. wire of 10 W.S.G. for L.T. line and 8 W.S.G for 11 KV to 33 KV lines is used
for guarding.
The first lacing should be at a distance of 750 mm from the pole. Other lecing are
tied at a distance of 3 meter from each other.
The vertical distance between conductor and guarding in mid span should be
minimum 610 mm for L.T. and 1220 mm for H.T line.
The vertical distance between L.T. line guarding cross arm and neutral should be
610 mm (2 ft.) and the length of cross arms should be 750 mm (2 ½ ’) .
The clearance between line and guarding cross arm for 11 KV, 22 KV and 33 KV
line should be 650 mm (2 ¼’), 750 mm (2 ½’) and 840 mm (2 ¾’) respectively.
There is no need of guarding for lines above 66 KV, as their circuit breakers are
sensitive. The breaker trips when conductor snaps thereby isolating the line.
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AT 11 KV LEVEL
DISTRIBUTION TRANSFORMER
Introduction
A transformer is a static piece of equipment with two or more windings, conductively disjointed,
but magnetically coupled by a time varying magnetic field, meant for transferring power from one
voltage level to other. A distribution transformer is one of the main components in a distribution
system network. Major faults in the transformers can cause extensive damage which not only
interrupts electricity supply but also results in large revenue losses. Poor/inadequate maintenance in
the areas of oil leakage, oil quantity, and critical accessories such as tap changers, bushings and
protective instruments is the main reason for transformer failure. With appropriate on site actions
like proper commissioning procedure and maintenance the useful life of the transformer can be
extended.
Scope:
This operational guideline is intended to carry out the fundamental checks on Transformer for its
maintenance and while taking it into service. This requires that the concerned SDO should prepare
the action plan and ensure the availability of necessary tools and tackles to carry out this activity.
Prerequisites:
Ensure that necessary permit has been taken. Feeding Sub-station is responsible for providing
outage and PTW. The working party is responsible for ensuring isolation. Ensure that the
transformer is de-energized, isolated & grounded.
Working party should ensure the availability of proper tools and accessories, safety apparels, spares
and consumables required for carrying out the work.
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a) For oil filled Distribution Transformers
S Type of Item Frequency Points to be checked Action to be taken in case of any
No Check anomaly
a) Silica Gel should be blue. a) If not, replace with blue silica gel.
As and when b) If any defect in body/cup, replace it
Physical required/Half b) No crack in body of breather & oil cup. c) If not oil filling to be done in cup up to the
1 condition Breather Yearly c) Oil level in oil cup should be up to the mark mark
2 Physical Oil leakages As and when a) Check for any oil leakage from a) Oil leakage to be attended at site, if not
Condition required/Half transformer tank, radiators, HV-LV possible at site then transformer to be
yearly bushings & any gasket joint etc. sent to work shop.
3 Physical Oil level As and when a) Oil level to be checked in gauge. a) If oil level not up to the mark then oil top
Condition required/Half up to be done immediately with fresh oil.
yearly
4 Physical Palm connector & Yearly a) Check for any arcing/pitting mark on a) If any defect Palm connector & AL bus
Condition AL bus-bar Palm connector & AL bus-bar. B) Check for bar to be replaced separately.
any discoloration due to local heating.
5 Physical HV-LV bushings Yearly a) Check for any crack/flash mark on HV- a) Defective Bushing to be replaced. b)
Condition LV bushings if any. b) Check for dust on Bushing to be cleaned with dry cloths.
HV-LV bushing.
6 Physical Tank body & Yearly a) Check for dust & rust on transformer a) Tank body & radiators to be cleaned. b)
Condition radiators body& radiators. painting is to be done if required.
7 Physical Tank body Yearly a) Tank body should be earthed at two a) If not, tank body earthing to be done at
Condition earthing placed with separate earthing point. two places.
8 Physical Neutral earthing Yearly a) Neutral should be earthed at two placed a) If not, neutral earthing to be done at two
Condition with separate earthing point. places.
9 Physical Arcing horns Yearly a) Check for pair of arcing on each phase of a) If not, then arcing horns to be fitted.
Condition HV bushing. b) Arcing horn alignment to be done.
b) Check for alignment of arcing horn.
10 Electrical Earth resistance Yearly a) Earth resistance should be = <1 Ohm a) If not then check for earthing pit or go
for new earthing
11 Electrical IR Value Yearly a) IR value shall be equal for all three a) If not then recheck the IR values.
phases for HT-E, LT-E, HT-LT. b) If value are lower then the values
b) Normally IR value shall be minimum specified then plan for
100 MΩ for HV & 50 MΩ for LV overhauling/replacement.
windings at the temp of 50°C. c) If IR value decreased more than
c) Compare previous & present IR 20% then need to investigate.
value.
12 Electrical Oil BDV Yearly a) BDV of transformer oil have to be greater a) If oil BDV is less then 30KV then plan
than 30 kV (avg) at 2.5mm gap. for overhauling/replacement.
13 Mechanical HV-LV termination Yearly a) Check for intactness of HV-LV a) If not tightening HV-LV nut-bolt and
termination, cleating for LV leads & HV accessories to be done.
cable. b) Tension on HV-LV terminals due to
b) Check for any tension on HV-LV cable/ conductor to be rectified.
terminals due to cable/ conductor.
14 Mechanical Vibration in As and when a) Check for any abnormal sound from a) If abnormal sound observed then keep
transformer required/yearly transformer. There should be a healthy Watch/plan for overhauling/replacement.
humming sound.
15 Electrical Thermoscanning As and when a) Check for thermo scanning half yearly/ a) Take corrective action if hot spot and
required/Half before and after of planned maintenance other abnormality detected.
yearly during pre and post maintenance visit.
16 Electrical Oil Every five year a) In addition to Oil BDV given additional a) If results are not with in limit then
of service test to be conducted on oil every five years transformer to be sent for overhauling at
of service; Water content<35PPM, Tan work shop.
delta<0.5, Resistivity>1.0X10^11ohm-cm,
Acidity<0.15mg KOH/g, Sludge-0% by wt,
and Flash point>125
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(i) Note: For Mobile Trolley Transformers including above checks following additional checks
to be conducted:
2 Physical Tyre As and when a) check for condition of tyres. a) If damaged then plan for rectification.
Condition required/Half b) Check for air pressure in tyre. b) If not ok then plan for filling of air.
yearly
3 Physical Earthing As and when a) Check for earthing between transformer a) If not ok then rectification to be done.
Condition required/Half to earthing point provided on trolley.
yearly
Minimum/Maximum required
S. No Type of test Test Significance Frequency
Values
Electrical BDV Poor oil BDV shows ingress of moisture, dust Yearly >30 KV
and carbon particles
1
Chemical Water Content Water(Moisture) will dissolve in insulating oil 5yearly/as and <35 PPM
and will contribute a hazard not only to the di when required
electric performance of the oil itself but also to
the solid insulation immersed in oil
2
Chemical Tan Delta It is a good value to indicate the quality of 5yearly/as and <0.5
Insulation. High value of DDF indicates the when required
presence of contaminants, deterioration products
such as water , Oxidation products, metal
Soaps, soluble varnishes and resins.
3
Chemical Flash point It is the minimum temperature at which heated 5yearly/as and >125
oil gives off sufficient vapour to form a flammable when required
mixture with air
4
Chemical Resistivity It is the resistance between the opposite 5yearly/as and >1x10^11ohm-cm
phases of a centimeter cube of the liquid. IR of when required
the windings in a transformer depends on the
resistivity of the oil also. Low resistivity
indicates the presence of moisture and or
Conductive contaminants in Oil.
6
Chemical Sludge content sludge is oil deterioration products or 5yearly/as and 0% by weight
contaminates, or both which are insoluble in oil when required
7
Chemical Acidity measure of free organic and inorganic acids 5yearly/as and <0.15mg of KOH/g
present together in the oil when required
8
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Significance of tests & frequency of transformer oil & required value:
2 Physical Enclosure, Doors, Yearly a) Check for dust & rust on enclosure & HV- a) Enclosure & HV-LV cable box to be
Condition marshalling Box LV cable box. cleaned.
3 Physical Enclosure doors Yearly a) Check for doors are properly closed or a) Ensure all doors shall be properly
Condition & marshalling box not. closed.
Door b) There should not be any open space at b) Any open space/gap to be filled with
cable (HV & LV) inlet &earthing strip. insulating material.
4 Physical Marshalling box Yearly a) check for working/setting for thermo stat. a) Proper setting to be done if required.
Condition b) check for working and physical condition b) Energy meter should be in working
of energy meter. condition.
c) Check for working for lamp. c) Lamp should be switched off when door
is closed.
5 Physical Active part Yearly Check for dust deposition over core coil Dust cleaning to be done with the help of
Condition assembly of transformer. air blower if required.
6 Physical Enclosure Yearly a) Enclosure should be earthed at two a) If not, tank body earthing to be done at
Condition earthing placed with separate earthing point. two places.
7 Physical Neutalearthing Yearly a) Neutral should be earthed at two placed a) If not, neutral earthing to be done at two
Condition with separate earthing point. places.
a) If not, then check for earthing pit or go
8 Electrical Earth resistance Yearly a) Earth resistance should be = <1 Ohm for new earthing
9 Electrical IR Value Yearly a) IR value shall be equal for all three a) If not then recheck the IR values.
phases for HT-E, LT-E, HT-LT. b) If value are lower than the values
b) Normally IR value shall be minimum specified then plan for
100 MΩ for HV & 50 MΩ for LV overhauling/replacement.
windings at the temp of 50°C.
10 Mechanical HV-LV termination Yearly a) Check for intactness of HV-LV a) If not tightening, HV-LV nut-bolt and
termination. accessories to be done.
b) Check for any tension on HV-LV b) Tension on HV-LV terminals due to
terminals due to cable. cable to be rectified.
11 Mechanical Vibration in As and when a) Check for any abnormal sound from a) If abnormal sound observed then keep
transformer required/yearly transformer. There should be a healthy Watch/plan for overhauling/replacement.
humming sound.
12 Electrical Thermoscanning As and when a) Check for thermo scanning half yearly/ a) Take corrective action if hot spot and
required/Half before and after of planned maintenance other abnormality detected.
yearly during pre and post maintenance visit.
13 Electrical Exhaust fan As and when a) Check for working of exhaust fan. a) Ensure for working of exhaust fan.
required/Half
yearly
Authorization
The SDOs will ensure that the operational directives and guidelines are followed at every level. The
compliance report provided as Annexure is to be duly signed by JE and counter signed by SDO and
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the same has to be kept as record. The record may be available with respective SDO / JE should be
presented for verification during the audits.
Implementation
The SDO shall be responsible for implementing these operational guidelines while commissioning
of Transformer. Detailed record of the activity has to be maintained separately.
Review:
The Executive Engineer will be responsible for reviewing this directive every two years or as
necessary in accordance with the revised standards (IS & IEC) and also from learnings observed
during the commissioning activities.
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RING MAIN UNIT (RMU)
Introduction:
Ring Main Unit (RMU) is used to make a ring system in electrical network to provide the reliable
supply to the people we served. RMU is very compact as compared to old type Oil & Air Circuit
Breakers. The chamber of RMU is filled with Sulphurhexafluoride (SF6) gas for insulating purpose.
This system change is taking place worldwide, since each of previously used insulating and arc-
quenching media, such as air and oil, have their own more or less serious disadvantages:
Air-insulated systems take up a great deal of space and, in extreme climatic or environmental
conditions, require maintenance.
Oil-insulated systems although on the whole well protected against external influences, pose a
considerable safety risk in the event of an internal fault.
Scope:
This operational guideline is intended to carry out the fundamental checks on RMU for its
maintenance and while taking it into service. This requires that the concerned engineer should
prepare the action plan and ensure the availability of necessary tools and tackles to carry out this
activity.
Prerequisites:
Ensure that necessary permit has been taken. Feeding Sub-station is responsible for providing
outage and PTW. The working party is responsible for ensuring isolation. Ensure that the Cable is
de-energized, isolated & grounded.
Working party should ensure the availability of proper tools and accessories, safety apparels, spares
and consumables required for carrying out the work.
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S.No. Description Range/Value/Status
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Tests:
* Note:– All Tests to be carried once in a year with the help of Metering & protection department.
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Single Line Diagram of RMU Connectivity
Load Break
Circuit Switch
Breaker
Maintenance Activity:
General Maintenance
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RMU to be isolated after obtaining PTW no. from the Feeding Sub-station.
Ensure that incoming supply is switched OFF by physical verification of the upstream
Breaker/Isolator/Grid. Also ensure that Voltage presence Indicating system - LED’s
should not blink in the RMU.
Open the Circuit Breaker and Isolator.
Close the earth switch.
Authorization
The SDOs will ensure that the operational directives and guidelines are followed at every level. The
compliance report provided as Annexure is to be duly signed by Junior Engineer and counter signed
by SDO and the same has to be kept as record. The record may be available with respective SDO /
JE and should be presented for verification during the audits.
Implementation
The JUNIOR ENGINEER shall be responsible for implementing these operational guidelines while
commissioning of RMU. Detailed record of the activity has to be maintained separately.
Review:
The XEN will be responsible for reviewing this directive every two years or as necessary in
accordance with the revised standards (IS & IEC) and also from learnings gained during the
commissioning activities.
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UNDERGROUND CABLES
Introduction
The underground cable network of any electricity distribution utility is a vital component of the
LV/HV network of the system. It has a several unique benefits over overhead networks. In
particular, they have:
The reliability of the underground distribution network directly affects the reliability of the overall
system and ultimately the overall customer satisfaction.
Scope
The operational guidelines apply to DHBVN engineers & any of Business Associates involved in
Testing & Repairing of Cable faults being carrying out for maintenance of electricity distribution
system.
Prerequisites
Ensure that necessary permit has been taken. Sub-Divisions & Systems are responsible
for ensuring isolation of the faulty cable for both ends & providing the PTW. Ensure that
the cable is de-energized, isolated & grounded.
The Business Associates should ensure the availability of proper tools and accessories,
safety apparels, spares and consumables required for carrying out the work.
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Directives & Checks
Preventive-Corrective
Abnormality Causes/ Effect
action plan
External
Insulation Damaged by external agency Ensure Patrolling of cable routes
damage
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Minimum permissible Bending radius (Table1)
PILC XLPE
1C 3C 1C 3C
S. No Test UG Cable
Phase to Ground and Phase to Phase to be tested
with 2.5/5.0 KVmeggar for one minute or
till reading stabilized. Minimum IR value
1 Meggar
should be 50 M ohms.
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Depth of the cable (Table-3)
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Current Carrying Capacity (Amps)
Nominal Size of
S. No. Cable (Sqmm)
for 11 kV level
In Ground at 30˚C In Duct at 30˚C In Air at 30˚C
Authorization
The SDOs will ensure that the operational directives and guidelines are followed at every level. The
compliance report provided as Annexure is to be duly signed by JUNIOR ENGINEERand counter
signed by SDO and the same has to be kept as record. The record may be available with respective
SDO & JUNIOR ENGINEER and should be presented for verification during the audits.
Implementation
The SDO shall be responsible for implementing these operational guidelines while Cable testing &
Repairing.
Review:
The Executive Engineer will be responsible for reviewing this directive every two years or as
necessary in accordance with the revised standards (IS & IEC)
CHECK LIST/ ANNEXURE- UG-1 ATTACHED
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HT OVERHEAD LINES
Introduction:
Overhead lines are the most cost effective and frequently used carriers for electric energy. Exposure
to environment accelerates deterioration; if this not detected and repaired quickly, some of it will
degenerate into serious problems with time. To increase line loading and increase quality of power
supply, frequent inspection programs is required to locate and repair any significant failure at the
earliest possible stage.
Frequent failure in the Overhead lines can cause extensive damage to the insulator and other
electrical & earth joints which not only interrupts electricity supply but also results in large revenue
losses. Poor/inadequate maintenance in the areas of pole, span length, non-tension electrical joints,
conductor spacing, line stay leads to the instability in the electrical and mechanical parameter which
reduce the life of the line. With appropriate on site actions, like proper maintenance procedure, the
useful life of the overhead lines can be extended.
Scope:
This operational guideline is intended to carry out the fundamental Line Survey / Checks for its
maintenance and while taking it into service. This requires that the concerned engineer should
prepare the action plan and ensure the availability of required materials, tools and tackles to carry
out this activity.
Prerequisites:
Ensure that necessary permit has been taken from feeding sub-station officer who is responsible for
providing outage and PTW.
The Operating personnel is responsible for ensuring de-energization, isolation and properly
grounding the network where the activity has to be carried out.
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If there be any DT within the working zones, the G.O (Gang Operated Switch) of all
DT’s should be OFF to avoid any back feeding from downstream.
During fixing the crocodile clip of shorting links to the conductor, it should be careful :
Before connection the shorting clip to the conductor, the earthing terminal of
the shorting clip should be earth.
Before connecting the shorting clip to a conductor, it (conductor) should be
earth by earth stick & holding the earth stick on the said conductor, the
crocodile clip of shorting links should be fastened with the conductor by
wearing safety gloves & then the earth stick to be removed. Repetition of the
same process of other too conductors must also be ensured.
The Working personnel should ensure the availability of proper tools and accessories, safety
apparels, spares and consumables required for carrying out the work.
Clearance
LV 11 KV
Minimum clearances from any accessible point
The vertical clearance from the highest
2.5 m 3.7 m
point
The horizontal clearance from the
1.2 m 1.2 m
nearest point
Minimum Ground Clearance
Across the street 5.8 m 6.1 m
Along the street 5.5 m 5.8 m
Line erected elsewhere 4.6m 4.6m
Line with Insulated Conductor 4m 4m
Line crossing 11 KV & LT line 2.4m
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Checks & Directives: For 11 KV O/H Feeders
S.No. Description Range/Value/Status
1 Line Support a) Depth of the Pit should be1/6 of the
a) Pole - 11m pole size.
b) Stay b) Pit filling concrete ratio 1:3:6
c) BasePlate-450mm×450mm×75mm c) Pole should be straight & to be
i. GI wire-7/10 SWG erected as per drawing of DHBVN.
ii. Guy/Egg Insulator/Stay insulator d) Stay angle should be min.30°
iii. Tension screw max 45°& should be fix at every pole
iv. Anchor hook where the line has deviated by more
v. Stay collar than 5°,End poles & Branch out/tee off
vi. Thimble pole. It would erect as per DHBVN
d) Strut Pole guidelines.
e) Strut pole & flying stay should
be erect at the place where no provision
for stay has.
Strut pole pit shall be located at
a distance not less then 1.8m
from the pole.
The depth of pit shall be such
that at least 1.2 m of the strut is
buried in the ground.
f) Tension screw, Stay collar,
Anchor hook and all hardware fixing,
Nuts& bolts to be checked.
g) Egg insulators to be provided in
all stay wire to prevent electrocution of
animal / human being during rainy
season.
2 Line Hardware : All line Hardware should havesuitable
a) Strain Insulator (Disc insulator) mechanical load bearing strength
b) Strain Clamp &capacity to avoid any breakage.
c) Pin Insulator
d) Spindle
e) Top Hamper
f) V –arm
g) Channel arm
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Tests
1 Earth Resistance
Sag of HT line to be
tightened, if found loose.
Spacers to be provided
especially where span
length of lines is more.
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S. No. Description Range/Value/Status
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Maintenance Activity:
General Maintenance
Check visually, the condition of Pole base & alignment of pole. If the pole tilted, should be
straighten & rammed the pole base with brick bats after digging the earth around the pole base. If
any bend occurred at the mid of the pole, has to be changed & pole to be erected as per drawing
attached.
Check visually the condition of existing stay
Check the Condition & size of GI wire. It should be 7/10 SWG.
Check the Condition of Guy/Egg Insulator, if any damage or missing observed, should
be fix/replace.
Check the Condition of tension screw, if any damage observed , it has to be changed
otherwise to tighten the turn buckle ,if required
Check the condition of anchor hook
Check visually the Line Hardware
Condition of Disc Insulator, if there is any crack, flash mark on the surface of the disc,
disc should to be change.
Condition of strain clamp of disc insulator, If any crack or flash mark on surface, it has
to be change.
Condition of Pin insulator, if there be any flash mark on the insulator surface, it has to
be change otherwise check the tightness with the spindle.
Condition of Pin insulator spindle, if any damage or bend, to be change otherwise check
the tightness of the fixing nuts.
Condition of Top hamper; if any tilt observed at top hamper, it has to be straight or any
damage occurred to the metal part, it is to be change, otherwise check the tightness of
fixing nuts bolts.
Condition of the V-arm. if any damage occurred on V-arm or on the fixing clamp, it is
to be changed otherwise check the tightness of the fixing Nuts, bolts
Condition of channel-arm, if any damage occurred on channel-arm or on the fixing
clamp, it is to be changed otherwise check the tightness of the fixing Nuts, bolts.
All metal part to be painted by Primer &Aluminium paint for increasing the durability of
life span. Further all metal parts on the pole of line should be connected to proper earth.
Visual inspection of bare conductor -if any damage occurred on the conductor, it is to be
replaced the damaged portion by same conductor with sleeve joint & the joint is limited
to maximum 2 nos.per span. If any loose, conductor to be re-sagged from section to
section. Also maintain spacing between the conductors.,
Span length should be maximum 40 meter for urban & rural residential area & 60 meter
for rural field area if the length larger than above so mid pole to be provided.
Line should be sectioned at every 4/5 span apart.
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Inspection of Joints
All jumpers should be made by conductor of same as line conductor or by the next
higher size rating conductor & joints to be made by suitable C-wedge connector. Mid
span joint to be done by Suitable Sleeves & the joint is limited to 2 no. per span.
Anti-climbing device
It is installed around the pole to prevent unauthorized persons from climbing the
structure .Anti-climbing to be fixed on every pole where cable mounting as OH feeder.
Cable being taken up to top of line and jumper at cable end should be made through
properly crimped lugs and fitted with C-wedge connector with line.
Trimming of Tree-branches
To have proper clearance from HT line should be ensure in order to prevent from
transient faults.
Authorization
The SDOs will ensure that the operational directives and guidelines are followed at every level.
The survey report is to be duly signed by JUNIOR ENGINEER/project engineer and counter
signed by SDO and the same has to be kept as record. The record may be available with
respective SDO & JUNIOR ENGINEER and should be presented for verification during the
audit.
Implementation
The JUNIOR ENGINEER shall be responsible for implementing these operational guidelines
while execution of maintenance activity. Detailed record of the activity has to be maintained in
the System.
Review:
The Executive Engineer will be responsible for reviewing this directive every two years or as
necessary in accordance with the revised standards (IS & IEC) and also from learnings gained
during the commissioning activities.
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Components of an Overhead 11 KV (H.T.) Line of O/H
Lines
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CHECKLIST –Annexure-OH-1 Attached
DRAWING (STAY)
X Y Z
All dimensions in mm
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Total 49 Nos of Rounds (7x7 Nos)
Step wise winding
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HT AERIAL BUNCHED CABLE
Introduction
The AB cable network of any electricity distribution utility is a vital component of the HV
network of the system. The reliability of the AB cable distribution network directly affects the
reliability of the overall system and ultimately the overall customer satisfaction.
Scope
The operational guidelines apply to DHBVN& any of Business Associates involved in Testing
& Repairing of Cable faults being carrying out for maintenance of electricity distribution
system.
Prerequisites
Ensure that necessary permit has been taken. Sub-divisions are responsible for ensuring
isolation of the faulty cable for both ends & providing the PTW. Ensure that the cable is
de-energized, isolated & grounded.
Patrolling of AB cable feeder may be conducted to identify & removal of unauthorized
tappings before starting of the work.
Copper Screen of HT ABC must be shorted along with messenger wire at starting & End
points and joints with crocodile clamp shorting’s. So that all conductive paths may be
kept at zero potential/ Earth potential
AB cable joints should be made properly. AB cable should not be jointed temporarily. In
case of emergency, proper joints must be made the next day. For jointing of Messenger
wire, mid span joint sleeve should be used instead of binding wires.
Laying of AB Cables
It may be ensure that AB cable should not be dragged on roads/ footpaths etc. It must be laid by
use of rollers & pulleys. In case AB cable is laid through trees/ vegetation area, branches may
be trimmed to avoid abrasion on AB cables.
Characteristics of HT ABC
At initial stage:
In Majority of cases, sparking & hissing sound is developed between Copper screen &
Messenger wire of HT ABC because of improper connection between copper screen &
Messenger wire.
Later stage:
Outer Sheath burnt along the Messenger wire & damage of XLPE insulation due to heat of
sparking.
Sparking spot
Reason of Failure:
Design Snags-
Installation snags -
To connect copper screens to the messenger wire with at least 25 sqmm single core PVC
unarmored cable at both ends of the HT AB Cable section.
To connect Aluminum screens to the messenger wire with 2run of 50 sqmm single core PVC
unarmored cable at one side of HT AB cable section
DON’TS
Metallic /copper
Temporary screens
joints must beconnected to emergency
restricted. In messenger wire
case, with
while PVCtemporary
making single joint,
corecopper
AL 25screen
sqmm cable
continuity must be maintained. Standard joint must be installed at the
earliest possible.
Copper screens connected to messenger wire with fuse/ conductor strand wire.
Revised HT
S. No. Particulars Existing HT ABC Remarks
ABC
Potential on metallic
1 screen w.r.t. earth @ no 4.49 KV Negligible NA
Load condition
The outer most sheath is PE or PVC .Since the outer sheath is subjected to UV rays,
the outer sheath cracks & the metallic screen i.e. Copper screen is exposed to
moisture which oxidizes. In case of fault, the fault current would over heat the
location of high resistance of the metallic screen which damages the XLPE
insulation and causing total damages to HT ABC.
To enhance the reliability of HT ABC, the cross sectional area of metallic screen
needs to be increased. The area of metallic screen is given by
The outer sheath of HT ABC emits a fruity like smell in case of PE outer sheath
which attracts animals such as rodents or squirrel .Due to this, the rodent & squirrels
normally chew the outer sheath of HT ABC causing further exposure of the metallic
screen in addition to the cracking of the outer sheath due to UV radiation. This
oxidizes the copper screen .This enhances the resistance of the copper screen, thus
causing increase in I²R losses when the screen carries the fault current during short
circuit condition or when the cable insulation punctures due to an incipient defect in
the bulk of the insulation .This leads to the total damage of HT ABC.
The straight through joint should be as far as possible installed on the pole so
that there is no pulling force exerted on to the outer sheath of the cable or on
the outer tubing of the cable joint. During the jointing of the cables at initial
stage, the cable drum length may be planned in such a way that the joints falls
right at the location of pole. The conductor’s joints are done by using ferrules.
It is important to use a long barrel ferrule .If the short barrel ferrule is used, the
number of crimps that can be done is limited to four, depending upon the type
of crimping tool used and the conductor size.
Conductor Resistance:
Both the ends of ABC circuits are to be disconnected at the termination end. At
one of the ABC circuit, the phase conductors are to be shorted by known values
The integrity of metallic screen decides the system reliability, when a fault in
the ABC takes place .Unless the resistance is low, the fault current will not be
able to traverse to the earth to trip the system.
Insulation Resistance:
The test is carried out at the time of ABC installation and when scheduled
maintenance is taken up or whenever there is a problem in a ABC network. It
is a general assumption that if the Insulation Resistance (IR) is low, it is taken
for granted that the cable is defective .A simple approach can be followed
during maintenance work and by measuring the insulation resistance and
calculating the value of volume resistivity will give a good approach. This will
give a trend analysis of the ABC deterioration.
Capacitance:
The individual’s cores can be checked for the capacitance values for the HT ABC
both during the installation and during the maintenance schedule .Even the
individual cable drums can be measured for capacitance before laying or making a
joint. A typical capacitance value of a 95sqmm 11kv XLPE cable is about
0.3µF/km.
Preventive-Corrective
Abnormality Causes/ Effect
action plan
Flash over due to Phase to phase & Phase to
Ensure sufficient clearance
earth clearance at cable termination
Electrical Stress HT ABC /Termination failure due to Ensure 1ɸ AL. conductor PVC
improper connection between Earth braid at insulated unarmoured cable with
End termination & Messenger wire. thimble is used for connection
between Earth Braids &Messenger
Rating ABC
1C 3C
Testing of AB cables:
S. No Test HT ABC
Current Rating
HT ABC (Standard Sizes of Single core cable)
1 35 106
2 50 150
3 70 190
4 95 230
5 120 265
6 150 300
7 185 345
Implementation
The SDO shall be responsible for implementing these operational guidelines while Cable testing &
Repairing.
Review:
The XEN will be responsible for reviewing this directive every two years or as necessary in
accordance with the revised standards.
Power cables
Cablesare used for the transmission/distribution of electrical power and consist of three major
components:
Conductors
Insulation
Protective jacket
For cables operating at or above 6,000 volts between conductors, a conductive shield surrounds
each insulated conductor to equalize the electrical stress on the cable insulation. The construction
and requirements are specified in standards such as IS7098 and IEC 60502, IEC6084.
Shielded power cable components
The important steps in the cable jointing of medium voltage XLPE insulated screened
armoured cable
a. Strip the jointing ends of both the cables to be done i.e. stripping of outer sheath, armour, inner
sheath, insulation screen, core insulation and conductor screen. Longer end will be 1050mm and
other end 750mm for 33Kv XLPE 3*400 sq. mm cable. Park the tubes 1000mm and 500mm then
1000mm at the longest side of the cable.
b. All the conductor cores shall be joint with the help of jointing ferrule/mechanical connector and
its crimping by suitable crimping tool.
c. Fill up the space between the ferrule and the core insulation and the crimped portion in ferrule
with semi conducting clay, so that it forms a smooth and round profile with 2 mm.
e. Keeping conducting layer of core, wrap the self-amalgamating insulating tape so that the required
insulation thickness is built up. Ensure a tapered profile of the tape towards the semi conducting
layer of the insulation, the self-amalgamating tape should be stretched to 2/3 rds of its original width
while applying as shown in figure given below.
g. Apply semi conducting tape one layer half over lapped about 10mm on one side of metallic
shielding to the other end in the same manner as shown in figure given below.
h. Wrap 2 layers of self-amalgamating insulating tape, each half overlapped to cover the semi
conducting tape. Stretch the tape 2/3rds of width while applying as shown in figure given below.
j. Place the black stress control tube centrally over the joint. Starting at the centre shrink the tube
towards one end and then towards the other end until fully shrunk. Apply heat evenly throughout
the process. When completed adhesive will flow from the ends, wipe off excess.
Introduction
With power system becoming more complex, Fault level has also gone up. So in a substation, a low
resistance path to ground is necessary:
It provides safe passage to earth fault current to flow. E/F current flow through the earth
and may readily cause operation of fuse or E/F relay.
It provides low resistance path to fault current to ensure prompt & consistent operation
of protective devices under fault current.
It protects the equipment other than live parts from attaining potential. Under fault
conditions, frames & enclosures etc may attain high potential w.r.t ground. So these
non-current carrying parts should be connected to ground for the safety of the operating
personal & other human beings for discharging electrical energy to earth.
It protects the equipment from over voltages, HV surges resulting from lightning &
other causes.
It ensures safety of life from electric shocks by grounding all metallic structures and also
avoid hazardous voltage gradients by suitably designing the grounding system. The
potential of earthed body does not reach to dangerously high values during fault.
It ensure that ground potential rise does not have any dangerous effect on
communication system.
It plays an important role in increasing the reliability & continuity of supply service and
stabilizing the voltage conditions.
It has means of discharging feeders &equipments to ground before proceeding with
maintenance.
Attributes Of Good Earth Connection
Lowest soil resistivity.
Low electrical resistance to earth.
Good corrosion resistance.
Ability to carry high current repeatedly.
A reliable life of at least 30 years.
Low loop impedance path of earthing.
Statutory Requirement of Earthing - IE RULE 1956
All medium voltage equipment shall be earthed by two separate and distinct
Connections.
All metal supports, all reinforced and pre-stressed cement concrete supports of overhead
lines and metallic fittings attached thereto shall be permanently and effectively earthed.
For this purpose a continuous earth wire shall be provided and securely fastened to each
pole and connected with earth ordinarily at three points in every kilometer, the spacing
between the points being as nearly equidistance as possible. Alternatively, each support
and the metallic fitting attached thereto shall be efficiently earthed.
To obtain a low overall resistance the current density should be as low as possible in the medium
adjacent to electrode, hence dimension in one direction is made larger than other two, so a Pipe or
Rod has much lower resistance as compared to Plate of an equal area.
a) MS/GI
b) Copper
The material shall be resistant to corrosion in the type of soil in which it is to be used. However, for
Power transformer neutral, electronics earthing, etc. copper is used due to higher conductivity.
2. Equipment Earthing – Providing earth to the entire system (connecting frames of equipment
like motor body, transformer tank to earth) to ensure freedom from shocks to the personnel in
vicinity and provide current carrying capability to accept ground fault current permitted by over
current protective system without creating a hazard to the building/installation
Selection of Earthing System
Separate and distinct earthing systems have low current flowing thru’ the measuring device such
as relays and long distances need to be covered. So a combined and Direct grounding system is
more effective than the individual Earthing.
a) Large spread areas – Buried earth conductors with localized earth rods shall be the solution.
b) Compact installations – Uniformly spaced buried conductors with as many earth rod
electrodes or mesh of earth conductor to meet the required resistance.
Factors Affecting Earth Resistance
Following factors may affect the value of earth resistance.
1. Resistance of the earth electrodes.
2. Contact resistance between the electrode & the soil
3. Soil Resistivity
a) Moisture content of the soil
b) Chemical composition of the soil
c) Concentration of the salts dissolved in the contained water
d) Grain size & distribution, and closeness of packing or the soil
e) Soil temperature
4. Geometry of earth electrode – To obtain Low overall Resistance, current density adjacent to
the electrode should decrease rapidly with distance from electrode. This is done by making
dimension in one direction large. Hence, pipe, rod or strip has much lower Resistance as
compared to Plate electrode.
5. Use of Crushed stone/Gravel layer – The crushed stone surfacing (0.08-0.15m in depth) is
used to retard the drying up of soil and increase the contact resistance b/w the person’s foot
and earth. This allows a higher touch and Step potentials.
Where,
I= value of fault current in amperes,
t= operating time of the disconnecting device in seconds,
k= factor dependent on material of conductor
The continuity resistance of the earth return path thru’ earth grid should be maintained
d) Large
as low as HV and to
possible EHVlimits/stns -
the rise of potential0.5 ohms installation above the potential
of earthing
of zero/remote earth during the passage of fault current.
e) Industrial and Distribution s/stns - 2.0 ohms
However, in EHV s/stns in spite of low earth resistance, the GPR may be as high as
f)5kV. So thevoltage
Medium earth design has to V)
systems(415 be based- on the 5.0
tolerable
ohms limits of Step and Touch
Potentials.
If the earth fault impedance does not permit the O/C devices to operate and can’t be
reduced further, then RCDs or ELCBs are used to disconnect the circuit at fault.
Introduction
A switching device, which by the fusion of one or more of its specially designed and proportioned
components open the circuit, in which it is inserted and breaks the current, when the same exceeds a
given value for a sufficient time. The term fuse covers all the parts forming the complete switching
device.
Description
Fuse is a safety device and the weakest part of the electrical system. It consists of a small link of soft
metal, which melts when excessive current passes through it. The fuse wires are usually bare wires
and made of lead and tin. Lead alloy for small current and tinned copper wire issued for large
current. Upto 3 amperes load, lead fuse wires are used, up to 15 amperes alloy of lead and tin is used
and above 15 amperes, tinned copper wires are used. If a short circuit occurs anywhere in the wiring
system, an excessive current flows through the wires and fuse and if fuse operates properly, it will
melt, cutting of the current before any harm can be done. If the fuse fails to operate, the wire may
become hot enough to ignite the insulation, possibly causing a fire and it may harm the appliances
and fittings connected in the circuit. Fuses have a second function. Besides protecting in the case of
short circuit, they protect in the case of overload. If too many appliances are connected to one
circuit, more current will flow through the supply wires than the wires were meant to carry and will
cause the wires to be burnt and appliances, accessories connected to the circuits will also be
damaged. In such cases, the fuse, if properly selected, will melt or blow, thus protecting the wires,
appliances, accessories etc.
Fusing factor
The ratio of minimum fusing current and the current rating of fusing element. Or
Fusing factors = Minimum fusing current /Current rating of fusing element. Its value is always
more than 1.
Principle of operation
The operation of fuse depends upon the heating effect of an electric current. When the electric
current is increased in a circuit due to short circuits or over loads, it increases the rate of heat
generation, which will increase the temperature of the fuse wire and thereby the rate of heat
dissipation increases from the exposed surface of the fuse wire. The final temperature reaches to
To select the proper fuse wire to be inserted in a circuit two factors viz. (a) maximum current rating
of the circuit (b) current rating of the smallest size of wire of accessories is to be seen, the fuse wire
inserted should be of size so that when the current with reference to factors (a) and (b) is increased, it
should blow out. The type of wire to be selected to use as a fuse wire depends upon the type of load
connected to the circuit i.e. steady load and fluctuating loads. The steady load covers the heating
loads and the fluctuating load consists of motor, capacitor and transformer loads, all of which take
transient over current when they are switched into the circuit. In steady load circuits, the fuse forms
only the protection part of the circuit. Therefore, the fuse rating should be equal to or next greater
than the ratings of the smallest cable used in the circuit. But if a number of fuse wires are run in
parallel to augment the rating of fuse, total rating should not be equal to the product of rating of and
strand and number of strands used. In fluctuating load circuits, fuse should allow the short time over
current to flow without blowing. For this, it is necessary to select fuses of rated current greater than
that of the cable of the circuit. The fuse wire should always be inserted in live wires or phase of the
circuit, or otherwise even if the fuse blows out, the faulty circuit will be fade and would cause
considerable damage in case of leakage fault.
Introduction:
An Autorecloser can reclose automatically after a specific set duration so supply restoration on
transient faults is quick. And on a dead fault the nearest Sectionaliser operates and the healthy
network gets disconnected from faulty network so the supply is restored in healthy part of network
in short time.
Autorecloser:
An autorecloser is a circuit breaker equipped with a mechanism that can automatically close the
breaker after it has been opened due to the fault current. Autoreclosers are used in coordinated
protection schemes for overhead power distribution circuits. These circuits are prone to transitory
faults such as nearby lightning strikes, wind-borne debris, birdages, kite fault and tree touching the
lines and any transient arc on insulators because of rain or fog.
With a conventional circuit breaker or fuse, a transient fault would open the breaker or blow the
fuse, disabling the line until a technician could manually close the circuit breaker or replace the
blown fuse. But an autorecloser will make several pre-programmed attempts to reenergize the line.
If the transient fault has cleared, the autorecloser's circuit breaker will remain closed and normal
operation of the power line will resume. If the fault is some sort of a permanent fault (downed
wires, tree branches lying on the wires, etc.) the autorecloser will exhaust its pre-programmed
attempts to re-energize the line and remain tripped off until manually commanded to try again.
90% of faults on overhead power lines are transient in nature and can be cured by auto reclosing.
The result is increased reliability of supply.
Sectionaliser:
Sectionaliser is a load break switch but it can be opened on load but in the event of existing fault in
line it can be programmed to open in off load condition. A sectionaliser is not designed to interrupt
fault current. The sectionaliser records the fault current and circuit interruption by the autorecloser.
After one autoreclosing cycle if the fault current persists, the sectionaliser will open its branch
circuit during the open period of the autorecloser, thereby isolating the faulty section of the circuit.
In second reclose attempt the supply restored in healthy Ckt.
Scope:
This operational guideline is intended to carry out the fundamental checks on Autorecloser for its
maintenance and while taking it into service. This requires that the concerned engineer should
prepare the action plan and ensure the availability of necessary tools and tackles to carry out this
activity.
* Note: – All tests shall be carried as per condition of switchgear with the help of protection
department. Requirement of testing shall be decided by Sub-Division with help of protection data.
Maintenance Activity and check lists:
Routine Maintenance activity and check list: to be filled by Sub-Division and Autorecloser Team
1 Operational checks
a Position Indicator (Mechanical) OK Not OK
2 Electrical checks
i. Check the date and time in PTCC OK Not OK
LED indication on PTCC Breaker Close /
ii. OK Not OK
Open
Battery voltage ( Aux supply should be turn Should be
iii. OK Not OK
off ) 24VDC
iv. Auxiliary supply Normal Abnormal
v. Check history logs events in panel OK Not OK
vi. Current values on PTCC ( After switch ON ) OK Not OK
vii. Voltage values on PTCC ( After switch ON ) OK Not OK
Pressure
viii. Pressure reading of SF6 on PTCC OK Not OK
( RL Type only ) ____KPA
3 Environmental checks
i. Visual inspection for missing parts OK Not OK
ii. Cleaning of PTCC ( dust etc ) Yes No
iii. Cable entry point sealed in PTCC Yes No
iv. Tie / clamp support to umbilical cable OK Not OK
v. Visual inspection of any damages Yes No
vi. Presence of Earthing on PTCC panel and PT OK Not OK
vii. Presence of PT bushing insulated Caps OK Not OK
4 Status of Battery cell terminals, connecting links OK Not OK
5 PTCC panel door intactness (window + Main door) OK Not OK
6 Lock of PTCC panel door OK Not OK
7 Contact Life Status on WSOS Value ______%
8 Cleaning/dusting Modem
9 Cleaning/dusting of SIM card in Modem
S. No Checks Status
1 Operational checks
i Switchgear ON/OFF through PTCC OK Not OK
ii Switchgear ON/OFF manual (in 'Sectionaliser/ RL series' only) OK Not OK
iii Mechanical Interlocks OK Not OK
iv Switchgear tripping through Emergency Lever (in U Series OK Not OK
only)
v Position Indicator (Mechanical) OK Not OK
2 Electrical Test
a Local / Remote - ON / OFF OK Not OK
b LED indication on PTCC Breaker Close OK Not OK
c LED indication on PTCC Breaker Open OK Not OK
Electrical interlock - Enable / Disable switch OK Not OK OK
d OK Not OK
Not OK
e Battery voltage ( Aux supply should be turn off ) ( 24VDC ) OK Not OK
f Auxiliary supply Normal Abnormal
g Check/ Download WSOS history logs Yes No
h Current values on PTCC ( After switch ON ) OK Not OK
i Voltage values on PTCC ( After switch ON ) OK Not OK
j Pressure reading of SF6 on PTCC ( RL Type only ) OK Not OK
k Check PT fuse intactness and continuity OK Not OK
l ON / OFF operation through Battery OK Not OK
3 Environmental checks
a Visual inspection for missing parts OK Not OK
b Cleaning of PTCC panel, ACR ( dust etc ) OK Not OK
c Connection Check of Plugs and CAPM compartment OK Not OK
d Cable entry point sealed in PTCC OK Not OK
e Cable entry point sealed in Switchgear OK Not OK
f Stress on bushing due to cable/conductor connection OK Not OK
g Method of Conductor connection on bushing OK Not OK
h Tie / clamp support to umbilical cable OK Not OK
i Terminal Connectors OK Not OK
Authorization
The SDOs will ensure that the operational directives and guidelines are followed at every level.
During installation and taking handling over the check list provided in 5.2 shall be duly filled by
supervisor and checked by JUNIOR ENGINEER/project engineer and counter signed by SDO and
the same has to be kept as record. The record may be available with respective SDO & JUNIOR
ENGINEER and should be presented for verification during the audits.
Implementation
Review:
The XEN will be responsible for reviewing this directive every two years or as necessary in
accordance with the revised standards (IS & IEC) and also from learnings gained during the routine
trouble shooting and commissioning activities
LT ACB
Introduction
LT ACBs are used in our system for distribution at 415 V level. The incomer cables from the
Distribution transformers are connected to the incoming terminal of one or more ACBs and the
feeder circuits are taken out from the outgoing terminals of ACBs. The various ratings of LTACB
widely being used in distribution system are 400A, 800A, 1250A and 2000A. The guaranteed
technical particulars are as follows:
S. No Description Requirement
5 Utilization category B
6 No of Poles 3
The incoming and outgoing terminals are designed for cables as mentioned below.
Do not lift the breaker with ordinary crane hooks or ropes but by using hands.
Keep the breaker away from impacts and shocks during transportation.
Make sure that the surface on which the breaker is to be placed is leveled.
Ensure proper fixing of ACB, to the channels on which it is placed.
The earthing bolts of the ACB are to be connected to the earthing bolts of the ACBs on
either side, if the ACB is being placed between two ACBs, else if placed at one side, one
earthing bolt will be connected to the body earthing conductor of the substation and the
other end will be connected to adjoining ACB.
Ensure complete tightness of lugs, fixed on ACBs and take care that the contact area is
sufficient.
After completion of work, the handle (where applicable) is to be kept at office and the
ACB is to be kept in locked condition only.
Operation
Different ACBs have different operating procedure. The operating manual of the respective ACBs
are to be consulted for proper guidance.
Tripping of Short Circuit Magnetic release: A protection is required against short circuit faults,
where the current may be many times the rated current. It becomes desirable that the breaker trips
with minimum delay unless definite time delay is envisaged for the discrimination of up and down
stream breakers.
The Magnetic instantaneous trip fitted in the breakers is a U shaped magnetic core placed around
the load terminal of the breakers and across the open side of the core, an armature is provided. The
movement of the armature is controlled by a spring. The settings are pre-determined and cannot be
changed easily at site.
Introduction
The underground cable network of any electricity distribution utility is a vital component of the
LV/HV network of the system. The reliability of the underground distribution network directly
affects the reliability of the overall system and ultimately the overall customer satisfaction.
Scope:
The operational guidelines involved in Testing & Repairing of Cable faults being carrying out for
maintenance of electricity distribution system.
Prerequisites:
Ensure that necessary permit should be taken. Site In-charge is responsible for ensuring
isolation of the faulty cable for both ends & providing the PTW. Ensure that the cable is
de-energized, isolated & grounded.
The workman should ensure the availability of proper tools and accessories, safety
apparels, spares and consumables required for carrying out the work.
Directives & Checks
Abnormality Causes/ Effect Preventive-Corrective action plan
External
Insulation Damaged by external agency Ensure Patrolling of cable routes
damage
Type of Core 1C 3C 1C 3C 1C 3C
Authorization
The SDOs will ensure that the operational directives and guidelines should be followed at every
level. The compliance report provided as Annexure-I is to be duly signed by JUNIOR ENGINEER
and counter signed by SDO and the same has to be kept as record. The record must be available
with respective SDO & JUNIOR ENGINEER.
Implementation
The SDO shall be responsible for implementing these operational guidelines while Cable testing &
Repairing.
Review
The XEN and above shall review this directive every two years or as necessary in accordance with
the revised standards (IS & IEC).
Introduction
Overhead lines are the most cost effective and frequently used carriers for electric energy.
Exposure to environment accelerates deterioration; if the fault is not detected and repaired
quickly, some of it will degenerate into serious problems with time. To increase line loading and
quality of power supply, frequent inspection program is required, to locate and repair any
significant failure at the earliest possible stage.
Frequent failure in the Overhead lines can cause extensive damage to the insulator and other
electrical & earth joints which not only interrupts electricity supply but also results in large
revenue losses. Poor/inadequate maintenance in the areas of pole, span length, non-tension
electrical joints, conductor spacing, pole stay leads to the instability in the electrical and
mechanical parameter which reduce the life of the line. With appropriate on site actions, like
proper maintenance procedure, the useful life of the overhead lines can be extended.
Scope
This operational guideline is intended to carry out the fundamental Line Survey / Checks for its
maintenance and while taking it into service. This requires that the concerned engineer should
prepare the action plan and ensure the availability of required materials, tools and tackles to carry
out this activity.
Prerequisites:
Ensure that necessary permit has been taken from SDO/JUNIOR ENGINEER who is
responsible for providing outage and PTW.
The PTW has to transfer to Working personnel after ensuring de-energization, isolation
and properly grounding the network where the activity has to carry out.
The Working personnel should ensure the availability of proper tools and accessories,
safety apparels, spares and consumables required for carrying out the work.
Clearance
Minimum clearances from any accessible point
1 The vertical clearance from the highest point 2.5 m
2 The horizontal clearance from the nearest point 1.2 m
Minimum Ground Clearance
1 Across the street 5.8 m
2 Along the street 5.5 m
3 Line erected elsewhere (Bare) 4.6 m
4 Line erected elsewhere (Insulated) 4m
5 Line crossing 11 KV & LT line 2.4m
Notes:-
Conductor current ratings may be interpolated for cross sectional areas between those shown in the
Table.
*Conductors with at least one ‘Type A’ stranding shall be used for general wiring of craft.
Conductors with Type B stranding shall be used for any wiring where frequent flexing is involved
during use.
Line Support
a) Pole – 9 m
1
b) Base plate (450mm×450mm×75mm) a) Depth of the Pit should be1/6 of
c) Stay the pole size.
Line Hardware :
h) Insulator
i. Large Shackle for DOG &
RACOON
ii. Medium Shackle for RABBIT &
SQUIRREL
iii. Porcelain /PVC bobbin
i) Double line X- arm
2
j) Shackle strap - at section & end
pole
k) D-Clamp-for fixing shackle insulator
l) Line spacer FOR PHASE
CONDUCTOR
m) Wedge connector - for M/L Jumper
connection
n) Mini wedge connector - for cable
Pole bending
Increase of sag tension
Substandard material for
jointing
In perfect joint, due to minimum
resistance, current smoothly flows
through the conductors, generating
minimum heat.
Damaged service line to be
replaced and joint in service line
covered with insulated tape, T-
joints or straight joints.
Tests
S. No. Description Range/Value/Status
1 Earth Resistance
Maintenance Activity
General Maintenance
Check visually, the condition of Pole base & alignment of pole. If the pole is tilted,
should be straighten & rammed the pole base with brick bats after digging the earth
around the pole base. If any bend occurred at the mid of the pole, should be changed &
new pole to be erected.
Check visually the condition of existing stay
Check the Condition & size of GI wire. It should be 7/10 SWG.
Check the Condition of Guy/Egg Insulator-if any damage observed or is missing, it
should be fixed/replaced.
Authorization
The SDOs will ensure that the operational directives and guidelines should be followed at
every level. The survey report is to be duly signed by JUNIOR ENGINEER and counter
signed by SDO. The captured record must be available with respective SDO & JUNIOR
ENGINEER.
Implementation
The SDO shall be responsible for implementing these operational guidelines while execution
of maintenance activity.
Review
The XEN and above shall review this directive every two years or as necessary in accordance
with the revised standards (IS & IEC).
Check list/Annexure-LT OH Conductor
Introduction
The AB cable network of any electricity distribution utility is a vital component of the LV network
of the system. The reliability of the AB cable distribution network directly affects the reliability of
the overall system and ultimately the overall customer satisfaction.
Scope
The operational guidelines apply to site engineers & all of the workmen, who are involved in
Testing & Repairing of Cable faults, carried out during maintenance or breakdown activity.
Prerequisites
Ensure that necessary permit has been taken. Site-in charge is responsible for ensuring
isolation of the faulty cable from both ends & providing the PTW. Ensure that the cable
is de-energized, isolated & grounded.
Patrolling of AB cable feeder may be conducted to identify & removal of unauthorized
tapings before starting of the work.
AB cable joints should be made properly. AB cable should not be jointed temporarily. In
case of emergency, proper joints must be made immediately. For jointing of Messenger
wire, mid span joint sleeve should be used instead of binding wires
The in-charge should ensure the availability of proper tools and accessories, safety
apparels, spares and consumables required for carrying out the work.
Laying of AB Cables
It may be ensure that AB cable should not be dragged on roads/ footpaths etc. It must be laid by use
of rollers & pulleys. In case the AB cable is laid through trees/ vegetation area, branches may be
trimmed to avoid abrasion on AB cables. OH distribution box (3-Φ /1-Φ) should be mounted on
pole for giving service connection. Incoming cable of suitable size for Distribution box should be
jointed with ABC by Mini wedge connector/IPC.
Water ingress Leakage current through the Ensure Lug seal to be intact at outdoor
cable Insulation/cable failure, termination.
Corrosion in cable conductor &
Armor due ingress of water
Clearly check the phase of cable 1 line represent R phase, 2 line represent Y phase and 3 line
represent B phase.
Earthing to be provided on 4thor 5th pole though 4SWG GI wire connected from Neutral
through insulated piercing connector
Minimum permissible Bending radius
Voltage Level ABC
1C 4C
Authorization
The SDO will ensure that the operational directives and guidelines should be followed at every
level. The survey report is to be duly signed by JUNIOR ENGINEER and counter signed by SDO.
The complete record must be available with respective SDO & JUNIOR ENGINEER.
Implementation
The SDO shall be responsible for implementing these operational guidelines while execution of
maintenance activity.
Review
The XEN and above shall review this directive every two years or as necessary in accordance with
the revised standards (IS & IEC).
Electronic Energy meters are installed for all consumers for recording energy used by consumers.
Electronic energy meters of class 1 accuracy shall be provided at all consumers premises.
The entire metering system needs to be regularly monitored to prevent any loss of revenue and to
analyze transmission losses. Analysis of transmission losses helps in taking corrective steps in
reduction of losses and improving the efficiency.
M&P unit under SE (M&P) will be normally testing the meters and the metering system
periodically (once in 2 year). Since the metering system at consumer end have commercial
implication, there should be proper sealing arrangement for meters and metering system to prevent
any meddling by unauthorized persons. Authorized staff should have access to download the data
from meters. Meters should also be equipped with facility for remote communication of data to the
controlling station for online analysis. Tamper proof arrangements should be available in the
meters. All accessible points for data transfer (serial ports, modems remote communication ports
etc) shall have provision for sealing by authorized persons.
The regular testing and periodical checks on specific complaints were attended by M&P staff and
readings are downloaded by authorized maintenance staff. The random check on the entire metering
system and the condition may be necessary, to ensure regular attention to the metering system to
prevent any leakages. This counter check may be carried out by a neutral agency such as quality
control unit or an independent third party.
Various checks and cross checks to be made by the independent team are as follows-
Input/output cable terminals should be tight.
Check for type (Electronic/Electro-mechanical) &accuracy class of meters.
Check for any cut/puncture in service cable.
Service cable from LT network to meter shall be properly clamped on pole using cleat
and shall not be hanging/lose.
Consumer cable should be at adequate height, while crossing the street/road.
Check for foolproof arrangement of the MCCB.
Height of meter shall be adequate, so that reading can be visible properly while standing
in front of the meter.
The total No. of meters, at one pole shall not be more than 8.
The seals of the meter should be properly checked and there should be no visible cut
mark on any of the seals.
Check for the proper earthing of the system, meter metal body and structures of
metering equipment.
After physical inspection, reports will be prepared covering all aspects and the remarks will be
communicated to the concerned.
Booking of cases for tampering meters with assistance of Anti Power Theft Squad (APTS):
Vigilance team should be authorized to book cases on the consumers with the assistance of APTS in
case any fraud like tampering the meters, deviation of agreement conditions etc. will be detected.
Introduction
LT Feeder Pillar meticulously designed to provide higher safety, reliability and protection with due
consideration of aesthetic features. It is an outdoor type four way L. T. distribution pillar which is
suitable for 3 phase 50 HZ 440V AC system. The Pillar is made of finest quality steel sheet which
is vermin proof and adequately ventilated.
The feeder pillar box contains double door, both front and back side of LT feeder pillar box having
fully detachable solid hinges allowing 180 degree opening and secured by a chrome plated door
handle with tamper proof lock facility including lock. Both front and back side shall be capable of
opening with panel key.
Feeder pillar are designed to take care of all cabling arrangements through suitable cable clamps.
The bottom plate of pillars are easy to detachable and provide knock out holes for entering different
sizes of the cables as per requirement at site.
Junction Box should be used for different service cables at LT poles. These Junction box should be
directly connected from feeder pillar outgoing Cable and the Cable should be routed properly using
cleat and clamps. Mouth of end termination of the rising cable should be kept in such a way that
rain water shall not enter inside the cable i.e. the open mouth should be in downward direction to
avoid any damage to cable. Proper thimbles size shall be used for joining the end of cable to
junction box.
Precaution
1. Only skilled or instructed personnel with relevant technical knowledge and experience, who are
also familiar with the safety procedures required when dealing with modern electrical/electronic
equipment are to be allowed to use and/or work on the equipment. All work shall be performed
in accordance with the Electricity at Work Regulations 2005.
2. The equipment must be disconnected/isolated from the incoming power supply before removing
any protective covers or working on any part from which the protective covers have been
removed.
3. Before any maintenance work is carried out, the mains supply to the equipment must be
isolated/switched off.
4. All equipment of conductive material installed in these pillars must be grounded, unless double
insulated or access to it is restricted to use of a tool.
6. Any employee working on site must wear the appropriate protective clothing, e.g. reflective
vests, etc.
Check List
Panel Body of feeder pillar must be checked for any leakage of current before
touching/operating.
The 2 Nos. earth terminals at bottom of the feeder pillar should be properly earthed.
All the service cables has to be inserted/passed through bottom of feeder pillar and no
service cable shall be passed through any of the door. It will prevent the closing of the
feeder pillar door.
No cable/part of cable should be visible hanging out from feeder pillar.
Checking of Proper size of lugs/thimbles used.
Checking of tightening of incoming and outgoing feeder cables.
Introduction
LT fuse board shall be installed on One Pole for Plinth/Pole Mounted DT/H-Pole of the ratings
required at site. Insulated cable from LV side of DTs shall be connected to one side of fuse board
through proper size lug/thimble.
The arrangement and dimensions shall be as per the drawing below (all dimensions are in MM)-
3 Bakelite Sheet 1
Check List
Transformers Circuits
Loose
connection
both at HT
& LT side
Bird / Animal Hot Spots
Electrocution due to
passage of
time
Probable
Cause of Poor/
defective
Low BDV / DT failure earthing -
IR value neutral &
DT
Tampering by Continuous
Miscreants Overloading of
DT
Probable
Cause of
DT failure
Poor
Maintenance Frequent LT
of DT Cable Faults
Improper
Protection of
both HT and
LT side
a. tightness of nuts
b. tightness of oil seal caps/replace oil seal & gasket if required
Don’t apply M-seal or other material on HV/LV bushing to stop oil leakage as this may
causing flashover.
Check the HT/LT rod and replace if required.
Oil leakage from top plate can be attended by tightening nuts & bolts diagonally
Replace gasket if required.
OIL LEVEL
BREATHER
Moisturized (Pink) Silica gel should be replaced with new / re activated (blue) Silica Gel.
In case of new Breather, ensure to remove seal from breathing hole of oil cup.
During maintenance , the breather size and type to be checked & non transparent breather
should be replaced by transparent breather of recommended size as below:
Oil sample for BDV test should be taken in proper oil sample bottle. In case of low BDV
value take necessary action.
Higher unbalance current cause rise in winding temperature. This overheating of winding may
damage the inter-winding insulation level and so as to distribution transformer failure.
4. Continuous overloading of DT
Distribution Transformers are generally not recommended for continuous overloading. However
overloading for a short duration cannot be avoided. It is one of the prime responsibilities of the
utilities to keep a check on the loading of a transformer and should record the loading Patton on a
More the cable faults, more the fault current travels towards the transformer.
Improper protection system always invites the risk of damage of equipment. As Distribution
Transformers are one of Costliest & vital part of Distribution System, Special care must be
taken while selecting switching & protecting devices. Preferably at HT Side Ring Main unit
(RMU) / breaker should be used with appropriate Protective Relays in case of small DTs Drop
down Fuses (DD fuses) of appropriate ratings can also be used. At LT Side of Distribution
Transformers Appropriate rating of ACBs / MCCBs can be used.
In case of absence of proper protecting devices or installation of improper Rating / Size of fuses
the risk of DT failure became very high. This could be the due to:
Consistent overloading.
2 for DT neutral
1 body & fence for DT
2 for LA.
Earth value should be checked during planned shut down and earthing connections should be
tightened.
9. Cat/monkey electrocution
In many case, unnecessary trippings and DT bushings failures noticed due to Cat/ Monkey/ Birds
electrocution.
Pre inspection of scope of work to ensure less down time of PSD and material
requirement.
Proper LT Cable end terminations to be installed in order to prevent it from ingression of
water during to rains which turns in Cable fault. ( see Pics below)
For testing of above values should HT insulation tester should be set at 5000 V
LT to earth; Min. value =50 MΩ
For testing of above values should LT insulation tester should be set at 500 V
If the IR values are lower than 100 MΩ, then the DT should be sent to the transformer
workshop.
*Note: However, DT can function at IR value of 10 MΩ, but chances of failure increase for
Nuts, bolts & clamps of H.V. & L.V. connections should be tight.
Proper size of lugs should be used on LV/HV cable as to maintain proper voltage.
Defected palm connectors should be replaced. (Pitting on the surface causes HOT
SPOT)
During the maintenance palm & lug contact surface to be cleaned properly and
petroleum jelly to be applied to avoid rusting and hot-spots.
Earthing
Interturn
fault/ Aging
Fault at cable
box before LT joints &
LV HT bushing
failures
Probable
Cause of
Faults in
Power Short circuit
CT at inzone of
Saturation Transformers both sides
CTs.
Probable
Cause of
Faults in
WTI & OTI Power Anomaly in
relays Transformers on load tap
operation changer .
Low Insulation
intensity failure &
incipient core
faults shorting
Note down the temperature and record the maximum daily ambient temperature.
Check that temp rise is reasonable. In case of any abnormal variation, check the cooling
system of T/F. If the same is not found in order. Shut down the T/F for further
investigation.
Check against transformer oil level/ temperature. Top up with dry oil, if necessary.
Check for any oil leakage.
Check for any abnormal sound or excessive chattering. Shut down the T/F in case of
abnormal noise, for further investigation
Examine relays and alarm contacts and their operation, fuses etc. Check for relays
functioning clean or replace the contacts if required
Measure earth resistance of the (a) T/F body, neutral and other body parts, (b) Keep
proper record of test results. (Earth testing to be done during driest part of the season)
Examine Firefighting equipments and ensure that these are in order.
In case of bushing -Test oil for dielectric strength Dehydrate or replace the oil, if
necessary.
Use LT sleeve on 11 KV side
Earthing of panels
I.R. values with 2.5KV rating meggar. Convert it at 700 C and compare the values with
the value taken at the time of commissioning.
Earth resistance of the (a) T/F body, neutral and other body parts, Keep proper record of
test results. (Earth testing to be done during driest part of the season)
To reduce eddy current, proper earthing of transformer body top cover with body is
must.
DO’s
1. Ensure leveling of Transformer at the time of installation.
2. Ensure Buchholz & OTI / WTI are unlocked (in service position) before energizing the
transformer.
3. Fill transformer oil in the OTI / WTI pockets before fixing the temperature sensing bulbs
in the pocket.
4. Check air cell / bellow in conservator.
5. Ensure the mounting inclination of Buchholz relay (3-50) .Provide the suitable support if
the connecting pipe is too long to avoid false tripping of transformer on Buchholz.
6. Check operation of Buchholz relay by draining oil or injecting air as the case may be.
Adjust the floats & mercury switches if required.
7. Ensure Fire wall between the two transformers as per requirement.
8. Check Fire extinguisher / emulsifier system for protection of transformers.
9. Ensure earthing of transformer fence for safety of human being.
10. Ensure proper earth of transformer neutral as well as body as per ISS standard.
11. Ensure the radiator valves are open.
12. Charge the transformer at normal Tap with all protection in service.
13. Do ensure TAP position indicated by TPI with OLTC are matching.
14. Ensure phase marking as specified in the rating plate.
15. Check the oil level in Transformer main tank, bushings & OLTC as a routine practice
and maintain up to the marked level.
16. Bleed air pockets before energizing the transformer.
17. Always use filtered dry oil confirming to ISS 335 to top up the conservator if required.
Check BDV of oil used for top up (with minimum BDV-60 kV). Oil drum to be filtered
separately before filling oil in the transformer.
18. Check the oil for moisture contents (ppm), acidity & sludge as per ISS 1866.
19. Check the oil level in the silica gel breather oil cup and ensure that air passages are free
in the breather. Top up oil up to the mark if required.
20. Inspect the transformer, radiators, bushings, connected oil pipes for any oil leakage and
attend it immediately.
21. Attend the leakages on the bushing immediately.
22. Examine the bushings for dirt, deposits and coats and clean them periodically.
23. Provide adequate protection system for the transformer w.r.t its rated capacity.
24. Check protection circuit periodically.
25. Use appropriate size of fuse as per the rating of the distribution transformer.
26. Check & clean the relay alarm & trip contacts. Perform trip test.
27. Ensure WTI / OTI / PRV / PRD / MOG (oil level) gauges are in working condition with
free movement.
28. Ensure calibration of the temperature gauges / RTD’s / temperature sensors.
DONT’s
“SWITCH OFF” The battery charger, so that load is directly connected to the battery.
Observe load voltage for at least 15-20 minutes. It should not drop beyond rated
voltage.
The “DC UNDER VOLTAGE” And “AC MAINS FAIL” Alarms should operate.
“SWITCH ON” The battery charger. Initially the battery will draw a high current limited
to the maximum rating of the charger and then gradually reduce to the normal value.
After the current reaches normal value, reset the “DC UNDER VOLTAGE” Fault.
In case of separate float and boost charger, check the interlocking between “DC
CONTACTOR” (which connects the battery to float charger) and “AC CONTACTOR” of
charger.
Check operation of “EARTH FAULT RELAY” by temporarily grounding the +ve or –ve
terminal through a high resistance
Distribution
Lines
Aerial
Bare Insulated
Bunched Cable
Conductor Conductor
(ABC)
Electric
stress
Thermal Mechanical
Stress Stress
Probable
Cause of
Faults in
Cables
Joint
External Failure
Damage
Water
Ingress
Cables are generally laid directly in the ground or in ducts in the underground distribution system.
For this reason, there are little chances of faults in underground cables. However, if a fault does
occur, it is difficult to locate and repair the fault because conductors are not visible. Nevertheless,
the following are the faults most likely to occur in underground cables:
1. Open-circuit fault
2. Short-circuit fault
3. Earth fault.
When there is a break in the conductor of a cable, it is called open circuit fault. The open-circuit
fault can be checked by a megger. For this purpose, the three conductors of the 3-core cable at the
far end are shorted and earthed. Then resistance between each conductor and earth is measured by a
megger. The megger will indicate zero resistance in the circuit of the conductor that is not broken.
However, if the conductor is broken, the megger will indicate infinite resistance in its circuit.
When two conductors of a multi-core cable come in electrical contact with each other due to
insulation failure, it is called a short-circuit fault. Again, we can seek the help of a megger to check
this fault. For this purpose, the two terminals of the megger are connected to any two conductors. If
the megger gives zero reading, it indicates short-circuit fault between these conductors. The same
step is repeated for other conductors taking two at a time.
When the conductor of a cable comes in contact with earth, it is called earth fault or ground fault.
To identify this fault, one terminal of the megger is connected to the conductor and the other
1. Insulation Degradation
2. Joint Failure
1. Insulation Degradation
a) Electrical Stress:
Electrical stress is always present at the cable. The voltage applied at the three phases of a
cable is 120º apart. Due to this a rotating electrostatic field is produced. These electrostatic
field lines of force are perpendicular to the equipotential surface. That’s why electrical
stresses are there within the cable. These stresses increases due to the following factors:-
Phase to Phase & Phase to earth clearance at cable termination are not proper.
Core crossing above cut back area at cable termination.
Untreated screen cut back during installation of cable termination.
So the above mentioned points should be taken care while making cable termination, to
reduce the stresses in the cable.
In the Pic-1 it is shown that the temperature near the termination reaches to abnormal temperature
& thus the breakdown of the insulation takes place.
In the Pic-2 it is shown that how the electrical stresses vary from the closer of the cable core to the
outer sheath of the cable. Electrical stress is greater close to the core & slowly reduces as we move
away from the core to the outer sheath.
In the Pic-3 it is shown that while making joints in the cable mastic tape should be properly rapped
closer to the ferrule. Otherwise this also produces electrical stress on the cable.
b) Mechanical Stress:
The following reason produce Mechanical stresses on cable:-
c) Thermal Stress:
The following reason produce Thermal stresses on cable:-
Overloading.
High thermal resistivity of soil.
Improper electrical connections.
Chemical Attack due to environmental contamination.
PIC-1 PIC-2
Above Pictures show how cable gets faulty due to thermal stresses. In the second picture it is
also clear that due to abnormal bending radius, thermal stresses take place within the cable &
ultimately produces breakdown of the cable insulation.
Due to Poor & loose earthing connection fault current will not be able to pass to the ground
quickly. It will travel through the core for little bit longer time & this will produce heating on
the cable i.e. thermal stresses will bethere within the cable. So, cable earthing should be
properly connected with the Sub-station (s/s) earthing& the S/S earthing should be solidly
grounded.
PIC-1 PIC-2
PIC-2 in the above shows that if the outer sheath of the cable gets damaged then it will absorb
moisture from the atmosphere & the cable insulation gets deteriorated due to ingress of moisture.
So damaged outer sheath should be repaired & also while storing the cable, end caps should be
provided at both the ends of the cable. Otherwise moisture will enter through the cable ends.
PIC-1
2nd picture shows another cable joint box which got damaged due to some digging activity. Due to
the fact that cable routes are not known to the outside digging agency, they are damaging our cable
insulation very frequently while they carry out digging for their own need.
2. Joint Failure
Joint Box failures are very frequent & common phenomena in cables. There Are Lots Of reasons
for which Joint Box failure occurs. Some of them are discussed below:-
Lack of standard pit while jointing due to obstacles in vicinity causes mechanical stress in joints.
This in combination with moisture ingress leads to tracking path over insulation & ultimately leads
to insulation failure of joint.
Suitable & proper Support must be provided to Cable when it needs to be connected with over
Headlines / Distribution Transformers.As due to improper support, cable end terminations have to
bear excessive pressure & weight of Cable and may lead to failure of Cable end termination.
To prevent moisture ingress heat shrink end caps should be used which are available in our
stores.
Overloading of cable is to be avoided in any circumstances (especially in LT cables.)
Moisture affected cable should strictly be avoided during jointing. HS end caps should be
used for storage.
Joints are to be made by qualified jointers.
Good workmanship is to be maintained while jointing.
Flashed
/Punctured
or broken
insulators
Improper Damaged
Earthing jumper/Co
nductor
Probable
Cause of
Faults in
O/H Lines
Improper Earthing:
Overhead lines are the main part of electrical power distribution system. These are used to carry the
electrical power from generating station / Sub-station to load centers/ consumer’s point. There are
several types of faults occurs at lines and there are several causes of fault occurrence at Over head
lines.
There are mainly two types of faults in the electrical power system. Those are symmetrical and
unsymmetrical faults.
1. Symmetrical faults
These are very severe faults and occur infrequently in the power systems. These are also called as
balanced faults and are of two types namely line to line to line to ground (L-L-L-G) and line to line
to line (L-L-L).
Only 2-5 percent of system faults are symmetrical faults. If these faults occur, system remains
balanced but results in severe damage to the electrical power system equipments.
Above figure shows two types of three phase symmetrical faults. Analysis of these fault is easy and
usually carried by per phase basis. Three phase fault analysis or information is required for
2. Unsymmetrical faults
These are very common and less severe than symmetrical faults. There are mainly three types
namely line to ground (L-G), line to line (L-L) and double line to ground (LL-G) faults.
Unsymmetrical faults
Line to ground fault (L-G) is most common fault and 65-70 percent of faults are of this type.
It causes the conductor to make contact with earth or ground. 15 to 20 percent of faults are double
line to ground and causes the two conductors to make contact with ground. Line to line faults occur
when two conductors make contact with each other mainly while swinging of lines due to winds
and 5- 10 percent of the faults are of this type.
These are also called unbalanced faults since their occurrence causes unbalance in the system.
Unbalance of the system means that that impedance values are different in each phase causing
unbalance current to flow in the phases. These are more difficult to analyze and are carried by per
phase basis similar to three phase balanced faults.
.
Tree Branches in Vicinity of Line
Wedge Connector
3. Plan for Tree Pruning / Trimming
Faults due to tree contact can be reduced by using tree pruner. It is a device which is used to trim
the unnecessary branches of the trees touching to the overhead lines. Tree trimming by Tree
trimming instrument saves time to climb on tree every time.
Create awareness in the public to avoid sprinkle rice, eatables, flours balls near
the power lines. This can be done with the help of administration.
Bird flapper should be used at lines where there are excessing amount of birds.
(Pics shown below).
Bird nests should be removed immediately by taking emergency shutdown from
feeding Sub-station.
Poly pro is an insulation sleeve with excellent dielectric strength, UV
stabilized used for covering fault prone sections of OH conductors (Pics
shown below).
Bird Flapper
Bird Guard
Concrete poles shall be erected in such a way that the major axis is in line with
the direction of the power line.
Jerking and swinging of poles caused by sudden lifting as well as striking of the
poles with ground or other objects shall be avoided
Stringing of the conductors shall be done as soon as foundation concrete has
been cured and hardened and soil has been well compacted.
Proper muffing shall be done.
Pipe electrode
Rod electrode
Plate electrode
Reason of Failure:
Thermal stress
Mechanical stress
Stress develop due to Improper Bending Radius
o Ensure Proper Bending radius
Stress/ Abrasion develop due to improper clearance between poles & AB cable
suspended on suspension clamps
o Ensure proper clearance between poles & ABC
Stress develop due to Improper Span length
o Ensure proper span length
o Span Length should be depend on the size of the conductor/ABC cable
and pole height/type to maintain min. Sag & specified ground
clearance
o It would be 30-35 m for PCC pole
External damage
Insulation Damaged during installation due to improper Laying practices.
o Ensure use of Rollers/ Pulleys during installations.
Water ingress
Leakage current through the cable Insulation/cable failure, Corrosion in cable
conductor & Armor due ingress of water
o Ensure Lug seal to be intact at outdoor termination.
Recommendation :
• HT ABC failure rate found high – route cause found to be inadequate SC rating of
HTABC available in India because of lack of Indian regulations about HT ABC.
• So we have adopted South African standards for HTABC in our specifications and
persuade Indian manufactures to comply for the same. So new HTABC with Al wire
screen for 10KA for one sec fault current rating has been introduced, old HT ABC was
with copper tape screen for 0.25KA for one sec fault current rating. So father
reduction in faults
CHECK LISTS/
ANNEXURES
Date &
Name of Grid:
Time
Season
Pre-requisite for Maintenance
Caution Order/PTW No.
T&P/material/PPEs
Safety Cotton Rag
ACTIO
PERMISSI
S. ITEM TO BE FREQUEN STATU N
BRIEF DESCRIPTION OF WORK BLE
NO. INSPECTED CY S TAKE
VALUES
N
Note down the temperature and record the
Ambient Temp Hourly NA
1 maximum daily ambient temperature.
Check that temp rise is reasonable. In case of
any abnormal variation, check the cooling
Winding/Oil Temp Hourly 100° C
system of T/F. If the same is not found in order.
2 Shut down the T/F for further investigation.
Check against rated figures. In case of any
Load/Voltage Hourly NA
3 variation, check the TPI.
Check against transformer oil level/ Daily each Above from
Oil level in transformer
1 temperature. Top up with dry oil, if necessary. shift Min level
Daily each Above from
Oil level in bushings Check for any oil leakage.
2 shift Min level
Check for cracked or broken. Replace if Daily each
Relief Vent diaphragm NA
3 necessary. shift
Check for any abnormal sound or excessive
For internal abnormal Daily each
chattering. Shut down the T/F in case of NA
noise. shift
4 abnormal noise, for further investigation.
Firefighting equipments Examine them and ensure that these are in order. Monthly NA
19
Note the oil level in the inspection glass of NA
Bucholtz’s relay Monthly
20 Bucholtz’s relay.
Check for dielectric strength. Dehydrate the oil,
Oil in T/F and tap
if necessary. Keep continuous record of test Quarterly NA
changer
1 results.
2 Ventilators Check that air passages are free. Quarterly NA
3 Bucholtz’s relay Check proper operation by lowering the oil Quarterly NA
4 Forced cooling system Megger testing of motors(pumps) Quarterly NA
Checking transformer ground connections for
Quarterly NA
5 tightness.
6 ThermoSyphen Filters Quarterly NA
7 Earth Resistance Check for tightness of earth connections. Quarterly NA
Measure earth resistance of the (a) T/F body,
neutral and other body parts, (b) Keep proper
Quarterly NA
record of test results. (Earth testing to be done
8 during driest part of the season)
Inspect all moving parts, contacts, brake shoes,
On load tap half yearly NA
1 motor etc. Clean, adjust or replace as required.
Check acidity, PPM & BDV & compare with
Oil in T/F half yearly NA
2 standard results.
Check Tan delta,,Sp.Resistively , sludge
Oil in T/F contents, DGA test, compare it with standard yearly NA
1 results.
Test oil for dielectric strength Dehydrate or
Oil filled bushing yearly NA
2 replace the oil, if necessary.
3 Cable box Check for sealing arrangements for filling holes. yearly NA
NA
NA
Visual observation of transformers and Reactors by going round, should be made daily to check for
any variations in noise, vibrations and any abnormality/leakages from cooler fans, oil pumps,
radiators, valves etc.
Date &
Name of Grid:
Time
Season
Pre-requisite for Maintenance
Caution Order/PTW No.
T&P/material/PPEs
Safety Cotton Rag
ACTIO
Permissi
Sr. ITEM TO BE FREQUEN STATU N
BRIEF DESCRIPTION OF WORK ble
no. INSPECTED CY S TAKE
Values
N
Examine that switchgear premises doors, circuit N/A
1 General cleanliness Daily
breaker etc. for general cleanliness.
N/A
2 Oil Check oil leakage, if so level be also ascertained. Daily
Check for temperature by touch and for any unusual N/A
3 Tank Daily
noise and smell.
Alarms and lamp indication Test the alarm circuit for continuity and lighting N/A
Daily
4 circuit etc. circuit and earthing system.
N/A
5 Safety aids Check safety aids for proper operation/condition. Daily
Check for load conditions on 3 phases, adjust relay N/A
Load Daily
6 setting. If necessary.
Indicating and measuring Check, indicating and measuring instruments for N/A
7 Daily
instruments correct reading and being in proper working order
N/A
1 Auxiliary fuses Check that auxiliary fuses are intact. Weekly
Check oil level in gauges of the tank/poles/oil filled N/A
2 Oil level and gauges Weekly
bushing. Replenish oil if found below normal.
Check for chipped or broken insulator, excessive N/A
Bushing or insulators Weekly
3 dirt film.
Visual inspection to see that equipment is in N/A
Closing solenoid of air
4 operating conditions Drain condensation from air Weekly
cylinder, motor or spring
cylinder.
Visual (or otherwise) inspection to see that N/A
Latch and trip mechanism Weekly
5 mechanism is in operating condition.
Visual inspection to see that solenoid trip device is N/A
6 Tripping solenoid Weekly
in operating condition.
Check cabinet heaters and see that they are in N/A
Cabinet lights and heaters service during cold weather. Replace burnt out Weekly
7 lamps.
N/A
8 Power supplies and wiring See that all power control circuit switches are closed Weekly
Check for external obstructions to breathers and N/A
Breathers and vents Weekly
9 vents and condition of silica gel.
Check whether nuts and bolts are tight and jumpers N/A
1 Nuts, bolts & Jumpers etc. Monthly
are properly connected.
N/A
2 Drain plug Check that drain plug is tight. Monthly
N/A
3 Operation counter Observe and record reading of operation counter. Monthly
N/A
Check dielectric strength of the insulating oil in the
main tanks and oil filled bushings. Oil should be
Oil dielectric test and filtered or replaced if dielectric strength is found to
acidity test dependent on below 25 KV, or if there is a noticeable amount of Annual
actual tripping carbon in suspension on the bottom of the tanks.
Also check ratio and phase angle adjustments, the
acidity of the oil.
22
Some breakers particularly those carrying high N/A
values of current have a tendency to develop contact
heating if left closed for long periods. Operating and
closing the breakers several times at intervals, as
23 Operation Annual
system operation permit, may alleviate the heating
by wiping the oxide from the contact surfaces, as
well as demonstrate that the breaker is in operating
condition.
ANNEXURE-CT/MAIN/-01
Date &
Name of Grid:
Time
Season
Pre-requisite for Maintenance
Caution Order/PTW No.
T&P/material/PPEs
Cotton Rag
Permissi
ITEM TO BE FREQUEN STAT ACTION
Sr. no. BRIEF DESCRIPTION OF WORK ble
INSPECTED CY US TAKEN
Values
N/A
Check for cracked or broken porcelain and
excessive dirt film and to undertake repair of
1 Insulators WEEKLY
chipped spots by painting with lacquer such as red
clay paint.
N/A
Blades and Check that blades are properly seated in the WEEKLY
2 contacts contacts..
Blades and N/A
3 latches and Check that blade latches where provided are WEEKLY
stops engaged.
Check that switches are properly locked in the open N/A
Locks and inter or closed position as required by padlocks or other WEEKLY
4 locks key type locks or interlocks.
Bolts, Nuts & Check bolts, nuts and jumpers for tightness. Apply N/A
1 Quarterly
Jumpers petroleum jelly on male and female contacts.
I.R,value and N/A
HALF
earth Check IR, value with 2.5KV megger and earth
YEARLY
1 resistance resistance. Check that double earthing is provided.
N/A
Check condition of contacts and refinish with fine
Auxiliary & file if burnt or corroded. Check contact spring HALF
2 operating rod and lever. Check closing and opening
limit switches YEARLY
position with respect to main switch contacts or
travel or motor mechanism.
N/A
To check for proper engagement of emergency HALF
Manual operating handle and further its operation is smooth YEARLY
3 operating Rod and satisfactory.
ANNUALL N/A
4
Line & ground Y
Blades and N/A
contacts ANNUALL
Y
5
N/A
N/A
N/A
N/A
Name of
Date & Time
Grid:
Season
Pre-requisite for Maintenance
Caution
Order/PTW
No.
T&P/materia
l/PPEs
Maintenance Activities
Permissible Stat Action
S.NO. BRIEF DESCRIPTION OF WORK Frequency
Values us Taken
1 All Earth pits MONTHLY N/A
HALF
1 All Earth connections at Earth pits. N/A
YEARLY
HALF
2 Check all equipments for double earthing N/A
YEARLY
HALF
3 Check all earthing conductors for adequacy & proper tightness. N/A
YEARLY
HALF
4 Check proper clamping of earthing pipe and earthing conductor. N/A
YEARLY
HALF
5 Check numbering of all earth pits. N/A
YEARLY
HALF
6 Check availability of Cast Iron lid for each earthing pit. N/A
YEARLY
Check exposed portion of earth conductor for Galvanizing or HALF
7 N/A
painting YEARLY
Check & ensure painting of Earth isolator box with Green HALF
8 N/A
colour for fast identification YEARLY
Check that each multicore cable is grounded through cable HALF
9 N/A
gland. YEARLY
Check and ensure that all power cables are earthed at one end HALF
10 N/A
only YEARLY
Check and ensure all multicore cables are earthed at switchyard HALF
11 N/A
end only or alternatively at one end only. YEARLY
Annexure- AR-1
Remarks:
Witnessed by:
1) Check that the colour of the silica gel in the breather is blue.
2) Check the breather for any cracks, holes, transparency and oil in the oil cup.
3) Check for any signs of No arcing/pitting mark on Bus-bar & palm connector.
4) Ensure that there is no leakage of oil from gaskets, flanges, valves, radiators,
bushings etc. Ensure oil level of conservator & cleaning of glass of conservator.
10) Check the earthing of fencing (enclosure) with two separate earths.
Witnessed by:
Test Results:
Witnessed by:
7) Check the earthing of the enclosure at two places with separate earthing point.
8) Check the earthing of the neutral with two separate earthing points.
Test Results:
Witnessed by:
1) Check that the colour of the silica gel in the breather is blue.
2) Check the breather for any cracks, holes, transparency and oil in the oil cup.
3) Check for any signs of No arcing/pitting mark on Bus-bar & palm connector.
4) Ensure that there is no leakage of oil from gaskets, flanges, valves, radiators,
bushings etc.
Test Results:
Witnessed by:
7) Check the earthing of the enclosure at two places with separate earthing point.
8) Check the earthing of the neutral with two separate earthing points.
Witnessed by:
Witnessed by:
Sub-Division
Item Description Status
A Type of Substation
B 11 kV Switchgear/RMU
1 Make
2 Physical Condition
(a) RMU Covers
(b) Earth Bus Bar Status
3 SF6 Preassure Gauge Indication
4 Voltage Indicating LED's
5 Grounding
6 Rubber Mat
7 Fault Passage Indicator
Witnessed by:
Check List:
Witnessed by:
Witnessed by:
Witnessed by:
Witnessed by:
Annexure- G.O.-1
3 Operating Rod
7 Locking Arrangement
Witnessed by:
Sr
No. Parameters Observations
1 Condition & size of GI wire. It should be 7/10 SWG OK Not OK Remarks
Condition of Guy/Egg Insulator, if any damage or
2 missing observed, should be fix/replace. OK Not OK
Condition of tension screw, if any damage observed
, it has to be changed otherwise to tighten the turn
3 buckle ,if required OK Not OK
4 condition of anchor hook OK Not OK
Visual Inspection
Condition of Disc Insulator, if there is any crack,
flash mark on the surface of the disc, disc should to
5 be change. OK Not OK
Condition of strain clamp of disc insulator, If any
6 crack or flash mark on surface, it has to be change OK Not OK
Condition of Pin insulator, if there be any flash
mark on the insulator surface, it has to be change
7 otherwise check the tightness with the spindle. OK Not OK
Condition of Pin insulator spindle, if any damage
or bend, to be change otherwise check the tightness
8 of the fixing nuts. OK Not OK
Condition of Top hamper, if any tilt observed at top
hamper it has to be straight or any damage occurred
to the metal part, it is to be change, otherwise check
9 the tightness of fixing nuts bolts. OK Not OK
Condition of the V-arm. if any damage occurred on
V-arm or on the fixing clamp, it is to be changed
otherwise check the tightness of the fixing Nuts,
10 bolts OK Not OK
Condition of channel-arm, if any damage occurred
on channel-arm or on the fixing clamp, it is to be
changed otherwise check the tightness of the fixing
11 Nuts, bolts OK Not OK
All metal part to be painted by Primer &Aluminium
12 paint for increasing the durability of life span OK Not OK
13 Visual inspection of bare conductor OK Not OK
Span length should be maximum 40m /50 m (Urban
14 /Rural) if the length larger than it , mid pole to be OK Not OK
Witnessed by:
Witnessed by:
Witnessed by:
Witnessed by:
Annexure LT ABC
Witnessed by:
Witnessed by:
Date &
Name of Consumer: Time
Account No-
Sub-Division -
Permissible Action
NATURE OF WORK Frequency Status
Values Taken
Any visible Cut mark or Puncture on
24 Months N/A
service cable
Checking all required information
24 Months N/A
written on meter box and are visible.
Whether Meter/MCCB is tightly fixed
24 Months N/A
or hanging
All Seals on MCCB & Terminals are
24 Months N/A
proper and not tampered
Consumer cable is at adequate height
Min 5.8
while crossing the street/road (from 24 Months
Meters
ground)
Accuracy of Meter 24 Months ±3%
Witnessed by:
Witnessed by:
Name of DT Date
DT Rating Time
Feeder Name
Permissible Action
NATURE OF WORK Frequency Status
Values Taken
LV cable from DT shall be routed
12 Months N/A
through palm/bi-metallic connector.
Witnessed by: