PART :A

Methodology For 132 KV ,66KV & 11KV Grid Stations

 Introduction:
An electrical grid is an interconnected network for electricity delivery from producers to
consumers. Electrical grids vary in size and can cover whole countries or continents. It consists
of:

 power stations: often located near energy and away from heavily populated areas
 electrical substations to step voltage up or down
 electric power transmission to carry power long distances
 electric power distribution to individual customers, where voltage is stepped down again to
the required service voltage(s). Although electrical grids are widespread, as of 2016, 1.4
billion people worldwide were not connected to an electricity grid. As electrification
increases, the number of people with access to grid electricity is growing.
 A transmission substation acts as a connection between several transmission lines. A
distribution substation acts as a middleman between the transmission substation and the
electricity consumer, lowering the transmission voltage to an appropriate level for
distribution to family homes and apartment buildings.
 Grid Station:
Substation is an assembly of apparatus, which transform the characteristics of electrical
energy from one form to another, say from one voltage level to another level, hence a
substation is an Intermediate link between the Generating station and consumers.
The most important part of electric power system is the Grid Station. A 132kv Grid
Station is that part of power system where high voltage of 132kv is received, stepped
down to 11kv and then given to different feeders that feed distribution lines. This whole
process is carried out by different parts and equipment.
 Elements of a Grid Station/substation
 Primary power lines.
 Ground wire.
 Overhead lines.
 Transformer for measurement of electric voltage.
 Disconnect switch.
 Circuit breaker.
 Current transformer.
 Lightning arrester.


 Switch yard
Switch yard is divided into three parts i.e., line bay, bus bar and transformer bay.
I. Line bay:
Line bay consists of

Wave trap: it traps the waves associated with 132kv line, which are used for communication
purposes.

Isolator: an isolator is installed which isolates the grid from the line. Isolators are “no load”
switches and are operated under no-load conditions. Its operating under load condition is very
dangerous as disconnecting high voltages will create a large flash.
Earth switch: an earth switch is also installed with the isolator, with the help of which we
ground any static charges before working/maintenance.
Line Circuit breaker: a high rating SF6 C/B is installed which operates automatically under
abnormal conditions and disconnect the grid from the line to avoid any damages. It can also be
operated manually and unlike isolators they can be operated under load conditions as they have
quenching media in them.
Line CT: after circuit breaker a current transformer is installed which calculates current and
give indication to the C/B when over current fault occurs hence acts as a protective device as
well as measuring device. Its CT ratio is generally 600/5A.
Isolator: again, an isolator is installed.
II. Bus bar:
After line bay it comes 132kv bus bar. It acts as a node point between line bay and transformer
bay. Bus bar helps in getting connections to several units (transformers) from a single 132kv
line. It can be used for incoming connections as well as outgoing ones.
PT: A potential transformer is also connected in parallel to 132kv bus bar through an isolator,
which measures voltage as well as give indication to over voltage relay under over voltage
conditions.
III. Transformer bay:
Transformer bay consists of
Transformer Isolator: after bus bar another isolator is used which isolates transformer from
the line. Operating it in ON load condition is very dangerous as high voltages produce arc while
connecting/disconnecting and they don’t have any quenching media.
CT: again, a current transformer is installed which calculates current and give indication to the
transformer C/B when over current fault occurs hence acts as a protective device as well as
measuring device. Its CT ratio is generally 200/5A.
Transformer Circuit breaker: again, an SF6 circuit breaker is installed which operates
automatically under abnormal conditions and disconnect transformer from the bus bar to avoid
any damages. It can also be operated manually and unlike isolators they can be operated under
load conditions as they have quenching media in them.
Lightning arrester (132kv): lightning arresters are devices which arrests and ground any
thunder storms falling on the power transformer and secure it from any harm. They are installed
on each phase at a relatively more height. They are grounded and have a non-linear resistor
which act as insulator for132kv voltage and as a conductor for higher voltages like that of
thunder storms and lightning bolts. In this way they ground these high voltages and provide
safety to the transformer and whole system.
Power transformer: then the power transformer is installed which steps down 132kv to 11kv.
(Power transformer is discussed in detail in the next section)
Lightning arresters (11kv): again, on the LT side of power transformer small lightning arresters
are used. And the purpose is again the safety of transformer from thunder lightning.
Cables (11kv): these cables give the transformer output to the 11kv incoming panel of the
respective transformer.
Power transformer
These are the step-down transformers with Delta circuit configuration on input side (HT) and
Star circuit configuration on output side (LT). This transformer steps down 132Kv to 11Kv. An
input of 132kv is given to the transformer primary coil through three input wires i.e., Red(R),
Yellow(Y) and Blue (B) and then 11kv is taken from secondary coil. The transformers use the
magnetic induction process to step down the 132Kv to 11Kv due to specific turn ratio in coils.
The main parts of a power transformer are its windings and bushes. Some other parts, also
known as accessories are:
Conservator oil: also called mineral oil. It helps in insulation of windings as well as in
cooling.
Conservator tank: it is fixed at an upper position and is filled about 70% to 80% of mineral
oil.
Radiator tubes: the circulation of transformer mineral oil takes place through these tubes, as
heated oil goes up and cooled oil goes down, hence continue the oil circulation for better cooling.
Cooling fans: these fans also help in transformer cooling. They are fitted below or at the side
of radiator tubes and provide cool air.
Buchholz relay: this relay is fitted near conservator tank and is also called float relay and gas
detecting relay. This relay detects the gases that are produced in the transformer under abnormal
conditions and operates to trip the transformer, hence avoid further damages.
Diaphragm: diaphragm is a cap shaped object and fixed on the top of power transformer, it
acts as emergency exit for transformer inner oil and gases.
Wheels: transformer has small wheels upon which it can be rolled from one place to another. As
they hold the transformer at a height from the ground or foundation so air flow is possible
beneath transformer.
Oil temperature indicator: this indicator detects the temperature of transformer oil. If the
transformer oil gets heated to such a temperature that can harm transformer, the oil temperature
indicator operates. It has two settings; 1st is alarm and the other is tripping.
Winding temperature indicator: this indicator supervises winding temperature. Like oil
temperature indicator it also has two settings, one is alarm and the other is tripping the
transformer.
Tap changer: this is an instrument connected with the power transformer that is used to vary
the transformer output. It actually changes the number of turns in the secondary coil of
transformer.
Dehydrating Breather: it is a tube on the side of transformer connected to conservator tank. It
extracts un-moisture air from the outside to fill the vacuum in the tank. To extract water particles
from the air, silica gel is used which is filled in the breather tube. Note that vacuum is created
when some gases are expelled through the same tube.
Transformer cooling
When the transformers operate continuously, as a result the core, coils, main tank and the
transformer oil heats up to a high temperature which can affect the operation, maintenance, and
output voltage of the transformer. In grid stations transformers are kept cool through three
different processes. That are:
ONAN: It stands for oil natural air natural. In this method fans are OFF and the transformer is
cooled by natural air, same is the case of oil which circulates by spontaneous motion of hot and
cold oil.
ONAF: It stands for oil natural air forced. This method is applied under a bit higher
temperature. Oil circulation takes place by itself while the air is provided by radiator fans.
OFAF: It stands for oil forced air forced. This method is applied under highest temperatures.
Fans are ON that provide more air and the circulation of oil is also speedup by oil circulation
pump.
 The main reason for using DC supply in substation or power stations is to provide a
continuous power supply to the control circuit. DC is a reliable source of power supply
because it can obtain from batteries. So, during power failure also, we have to provide the
continuous power supply to the control circuit
 Many towers also have extra wires running along the tops of the towers. These are ground
wires and are there primarily in an attempt to attract lightning.
 CT and PT are used where large quantities of currents and voltages are used. The job of CT
and PT is to reduce high current and high voltage to a parameter. With the help of this
parameter, we can measure the current flowing at high volume and voltage.
 Design
 Elements of a substation

Substations generally have switching, protection and control equipment, and transformers. In a
large substation, circuit breakers are used to interrupt any short circuits or overload currents that
may occur on the network. Smaller distribution stations may use recloser circuit breakers or
fuses for protection of distribution circuits. Substations themselves do not usually have
generators, although a power plant may have a substation nearby. Other devices such as
capacitors, voltage regulators, and reactors may also be located at a substation.

Substations may be on the surface in fenced enclosures, underground, or located in special-

purpose buildings. High-rise buildings may have several indoor substations. Indoor substations
are usually found in urban areas to reduce the noise from the transformers, for reasons of
appearance, or to protect switchgear from extreme climate or pollution conditions.

A grounding (earthing) system must be designed. The total ground potential rise, and the
gradients in potential during a fault (called touch and step potentials),[6] must be calculated to
protect passers-by during a short circuit in the transmission system. Earth faults at a substation
can cause a ground potential rise. Currents flowing in the Earth's surface during a fault can cause
metal objects to have a significantly different voltage than the ground under a person's feet; this
touch potential presents a hazard of electrocution. Where a substation has a metallic fence, it
must be properly grounded to protect people from this hazard.

 Location selection
 Selection of the location of a substation must consider many factors. Sufficient land area is
required for installation of equipment with necessary clearances for electrical safety, and for
access to maintain large apparatus such as transformers.

Where land is costly, such as in urban areas, gas insulated switchgear may save money overall.
Substations located in coastal areas affected by flooding and tropical storms may often require an
elevated structure to keep equipment sensitive to surges hardened against these elements.[8] The
site must have room for expansion due to load growth or planned transmission additions.
Environmental effects of the substation must be considered, such as drainage, noise and road
traffic effects.

The substation site must be reasonably central to the distribution area to be served. The site must
be secure from intrusion by passers-by, both to protect people from injury by electric shock or
arcs, and to protect the electrical system from misoperation due to vandalism.

 Design diagrams

The first step in planning a substation layout is the preparation of a one-line diagram, which
shows in simplified form the switching and protection arrangement required, as well as the
incoming supply lines and outgoing feeders or transmission lines. It is a usual practice by many
electrical utilities to prepare one-line diagrams with principal elements (lines, switches, circuit
breakers, transformers) arranged on the page similarly to the way the apparatus would be laid out
in the actual station.

In a common design, incoming lines have a disconnect switch and a circuit breaker. In some
cases, the lines will not have both, with either a switch or a circuit breaker being all that is
considered necessary. A disconnect switch is used to provide isolation, since it cannot interrupt
load current. A circuit breaker is used as a protection device to interrupt fault currents
automatically, and may be used to switch loads on and off, or to cut off a line when power is
flowing in the 'wrong' direction. When a large fault current flows through the circuit breaker, this
is detected through the use of current transformers. The magnitude of the current transformer
outputs may be used to trip the circuit breaker resulting in a disconnection of the load supplied
by the circuit break from the feeding point. This seeks to isolate the fault point from the rest of
the system, and allow the rest of the system to continue operating with minimal impact. Both
switches and circuit breakers may be operated locally (within the substation) or remotely from a
supervisory control center.

With overhead transmission lines, the propagation of lightning and switching surges can cause
insulation failures into substation equipment. Line entrance surge arrestors are used to protect
substation equipment accordingly. Insulation Coordination studies are carried out extensively to
ensure equipment failure (and associated outages) is minimal.
Once past the switching components, the lines of a given voltage connect to one or more buses.
These are sets of busbars, usually in multiples of three, since three-phase electrical power
distribution is largely universal around the world.

The arrangement of switches, circuit breakers, and buses used affects the cost and reliability of
the substation. For important substations a ring bus, double bus, or so-called "breaker and a half"
setup can be used, so that the failure of any one circuit breaker does not interrupt power to other
circuits, and so that parts of the substation may be de-energized for maintenance and repairs.
Substations feeding only a single industrial load may have minimal switching provisions,
especially for small installations.

This single-line diagram illustrates the breaker and a half concept often used in switchyards.Once
having established buses for the various voltage levels, transformers may be connected between
the voltage levels. These will again have a circuit breaker, much like transmission lines, in case a
transformer has a fault (commonly called a "short circuit").

Along with this, a substation always has control circuitry needed to command the various circuit
breakers to open in case of the failure of some component.

 Automation

Early electrical substations required manual switching or adjustment of equipment, and manual
collection of data for load, energy consumption, and abnormal events. As the complexity of
distribution networks grew, it became economically necessary to automate supervision and
control of substations from a centrally attended point, to allow overall coordination in case of
emergencies and to reduce operating costs. Early efforts to remote control substations used
dedicated communication wires, often run alongside power circuits. Power-line carrier,
microwave radio, fiber optic cables as well as dedicated wired remote control circuits have all
been applied to Supervisory Control and Data Acquisition (SCADA) for substations. The
development of the microprocessor made for an exponential increase in the number of points that
could be economically controlled and monitored. Today, standardized communication protocols
such as DNP3, IEC 61850 and Modbus, to list a few, are used to allow multiple intelligent
electronic devices to communicate with each other and supervisory control centers. Distributed
automatic control at substations is one element of the so-called smart grid.

 Insulation

Switches, circuit breakers, transformers and other apparatus may be interconnected by air-
insulated bare conductors strung on support structures. The air space required increases with
system voltage and with the lightning surge voltage rating. For medium-voltage distribution
substations, metal-enclosed switch gear may be used and no live conductors exposed at all. For
higher voltages, gas-insulated switch gear reduces the space required around live bus. Instead of
bare conductors, bus and apparatus are built into pressurized tubular containers filled with sulfur
hexafluoride (SF6) gas. This gas has a higher insulating value than air, allowing the dimensions
of the apparatus to be reduced. In addition to air or SF6 gas, apparatus will use other insulation
materials such as transformer oil, paper, porcelain, and polymer insulators.

 Structure

Outdoor, above-ground substation structures include wood pole, lattice metal tower, and tubular
metal structures, although other variants are available. Where space is plentiful and appearance
of the station is not a factor, steel lattice towers provide low-cost supports for transmission lines
and apparatus. Low-profile substations may be specified in suburban areas where appearance is
more critical. Indoor substations may be gas-insulated switchgear (at high voltages), or metal-
enclosed or metal-clad switchgear at lower voltages. Urban and suburban indoor substations may
be finished on the outside so as to blend in with other buildings in the area.

A compact substation is generally an outdoor substation built in a metal enclosure, in which each
item of the electrical equipment is located very near to each other to create a relatively smaller
footprint size of the substation.

At present, the demand for electrical power is growing rapidly, and this can be fulfilled by the
power generating substations. There are different types of power generating substations like
thermal, atomic, and hydro-electric. Based on the availability of different resources, substations
are building at different locations, but these locations may not be closer to load centers. The
actual power utilization can be done by the load center. So it is essential to transmit the power
from the substation to load center locations. So, high and long transmission networks are
required for this function.

Power is generated fairly in the level of low voltage level; however, it is inexpensive to supply
the power at a high-voltage level. For preserving high and low voltage levels a number of
switching as well as transformation stations have to be produced among the generating place &
customer ends. Generally, these two stations are named as electrical substations. This article
discusses different types of substations

A substation is an electrical system with high-voltage capacity and can be used to control the
apparatus, generators, electrical circuits, etc. The Substations are mainly used to convert AC
(alternating current) to DC (direct current). Some types of substations are tiny in size with an
inbuilt transformer as well as related switches. Other types of substations are very huge with
different types of transformers, equipment, circuit breakers, and switches.

 Substation design and engineering

 Building a new substation or retrofitting the old one is a complex process full of design and
engineering tasks to be worked on. The main steps in substation design and engineering are
as follows:8 steps to follow in power substation design and engineering
  Step 1 – switching system
 Selection of a substation switching system: ring bus, breaker-and-a-half, etc. based on
reliability requirements.
 Step 2 – key plan, location of components
 Preparation of a key plan which should show the location of all components of a
substation and their interconnections, as well as steel structures, control house, fire walls,
driveways, fence and property line.
 Step 3 – equipment selection and ordering
 Selection and ordering of equipment, which is usually done in a utility company by
a designated group of equipment experts.
 They specify transformers, breakers, etc., request bids form approved vendors, evaluate
the bids, place the order with a winning bidder, and participate in testing and commissioning
of equipment.
 Step 4 – engineering support
 Engineering support for licensing and permitting which includes preparation of necessary
drawings sealed by professional engineers, testifying at public hearings at the municipalities
where a new substation is planned to be built, ordering of noise studies and selecting means
of noise mitigation if needed.
 Step 5 – civil and structural design
 Civil and structural design which includes:
 Pile design
 Foundations
 Steel structures
 Control house
 Step 6 – electrical layout design

Electrical layout design which includes:

 Positioning of equipment
 Bus design
 Design of manhole and conduit system
 Design of auxiliary A.C. power system
 Selection of D.C. batteries and battery chargers
 Layout of control house
 Grounding and lightning protection design
 Step 7 – relay protection, SCADA
 Control design which includes:
 Relay protection and instrumentation system schematics and wiring diagrams
 Relay racks or panels
 Remote control and metering (SCADA – system control and data acquisition)

 Step 8
 Construction support which includes a resolution of technical problems discovered during
construction, ordering of additional materials, etc.
 Further details of major equipment
 Because selection of the major equipment is one of the most critical tasks in substation
engineering, there are a lot of details. These are just the part of some major equipment
ratings:
 Power transformer ratings
 Capacity including overload capability
 Cooling class
 Frequency
 Primary and secondary voltage
 Phase relation between primary and secondary voltages
 BIL for both high and low voltage sides
 Voltage regulation requirements: load and no-load taps
 Transformer impedance
 Sound level
 Circuit breaker ratings
 Rated maximum voltage
 Rated continuous current
 BIL
 Rated short circuit current
 Interrupting time
 Rated frequency
 Current transformer (CT) ratings
 BIL
 Rated current
 Rated frequency
 Number of taps and ratio for each tap
 Accuracy class
 Type (bushing CT, free standing, etc.
 Voltage transformer (VT) ratings
 Rated voltage factor
 Rated primary voltage (Up)
 Rated secondary voltage
 Accuracy power
 Accuracy class
 Voltage ratio error
 Phase or phase displacement error
 Rated thermal limiting output
 Disconnect switch ratings
 Rated voltage
 Rated frequency
 Rated current
 Rated short-time withstand current and duration
 Rated peak withstands current
 Rated short-time power frequency withstand voltage (rms) – To earth between breaks
 Rated lightning impulse withstand voltage (peak) – To earth between breaks
 Rated busbar transferring current
 Type of motor operation mechanism
 Switching capacitive current
 Switching inductive current
 Switching busbar transferring current Bus-transfer current
 Substation construction

There are nine main steps to build a substation to lower the voltage generated by transmission
lines, and it takes many tradespeople to meet the challenge. At each step, we adopt strict safety,
project quality and environmental protection practices.
 Steps
 Establish the work zone
 Prepare the substation site
 Excavate and lay the foundations
 Install the grounding grid
 Build the command building
 Backfill the foundations and substation yard
 Assemble the steel structures
 Install the electrical equipment
 Landscape and carry out the final inspection
1. Establish the work zone
Before carrying out any work, it is important to establish the work zone and fence it off to
ensure the safety of the access points.
Then, notices of work and site tags are installed to keep citizens informed throughout the
construction period. In addition, other sources of information including a Web page, an
Info-project line, project news bulletins and press releases are generally available to
citizens, who may also contact the project's community relations advisor.
Throughout the project, site supervisors ensure that all the actions undertaken meet
environmental, health and safety and quality standards.

2. Prepare the substation site

At this step, any trees growing in the work zone are cut down.Then, the ground is levelled and
earthwork is carried out.The construction team prepares the work site by carefully setting aside
the topsoil, which will be reused.
3. Excavate and lay the foundations
At this step, workers excavate the site, build the formwork, install the reinforcements and pour
the concrete.In addition to laying the foundations, we build all the underground concrete
structures, such as the recovery basin.
4. Install the grounding grid
The grounding grid is installed to ensure the safety of people and the equipment. Buried
underground, the grid redirects the fault current.
5. Build the command building
As its name suggests, the command building houses the control and protection equipment.Most
substations are automated and remotely controlled. Only the largest substations have permanent
technical staff on site since most are maintained by mobile teams.
6. Backfill the foundations and substation yard
Once the foundations have been laid, we backfill them and level the yard with granular material
(sand, gravel, rock, etc.) that is adapted to the site.
7. Assemble the steel structures
Once the concrete is set, steel structures are assembled to support the electrical equipment. Other
structures will support the control building.
8. Install the electrical equipment
Once the framework is built, we install the equipment on the foundations and steel structures.
Each piece of equipment is then connected to the control room, which is under construction.
We permanently fence off the new installations to ensure everyone's safety. Our technicians test
the equipment before the installations are connected to the power grid. Finally, we commission
the substation and ensure that the electricity is flowing.
9. Landscape and carry out the final inspection
The project ends with landscaping: we plant trees, create mounds of earth and do more work if
necessary.
We do earthwork, demobilize the site and carry out the final inspection to wrap up the project.
Only the operating equipment is left at the substation.

 Substation
A substation is a part of an electrical generation, transmission, and distribution system.
Substations transform voltage from high to low, or the reverse, or perform any of several other
important functions. Between the generating station and consumer, electric power may flow
through several substations at different voltage levels. A substation may include transformers to
change voltage levels between high transmission voltages and lower distribution voltages, or at
the interconnection of two different transmission voltages.

Substations may be owned and operated by an electrical utility, or may be owned by a large
industrial or commercial customer. Generally substations are unattended, relying on SCADA for
remote supervision and control.

The word substation comes from the days before the distribution system became a grid. As
central generation stations became larger, smaller generating plants were converted to
distribution stations, receiving their energy supply from a larger plant instead of using their own
generators. The first substations were connected to only one power station, where the generators
were housed, and were subsidiaries of that power station.
  Types

Substations may be described by their voltage class, their applications within the power system,
the method used to insulate most connections, and by the style and materials of the structures
used. These categories are not disjointed; for example, to solve a particular problem, a
transmission substation may include significant distribution functions.

 Types of Sub Stations

The different types of substations mainly include Step-up Type Substation, Step-down
Transformer, Distribution, Underground Distribution, Switchyard, Customer Substation, and
System Station.

 Step-up Type Substation

This type of substation gets the power supply from a near producing facility. It uses a large
power transformer for enhancing the voltage level for transmitting to the remote locations. In is
substation, the power transmission can be done by using a transmission bus to transmission lines.
This substation can also be a knock on the incoming power which is received by the generation
plant. The received power can be used to supply power to the operation of apparatus in the plant.
A substation includes circuit breakers for switch generation as well as transmission circuits in &
out of service as required.

 Customer Substation

This type of substation works as the major source of power supply for one specific business
client. The business case, as well as the requirements of technical, highly depends on necessities
of customers.

 System Stations

This substation includes the huge amount of power transfer across the station and it is called as a
system station. These stations only offer no power transformers while others do voltage
exchange as well. Typically, these stations supply the end-points to the transmission lines
creating from switchyards & supply the electrical energy for circuits that supply transformer
stations. They are important to long-term consistency. These stations are strategic services as
well as very costly to build as well as to maintain.Distribution Type Substation

Distribution type substations are placed where the main voltage distributions are stepped-down
to supply voltages to the consumers using a distribution network. The voltage of any two phases
will be 400 volts, and the voltage between neutral and any phase will be 230volts.
  Distribution Substation
 Step-down Type Substation

This type of substation is placed at different points in an electrical network. They can connect
different parts of the network and that are a source of sub-transmission or distribution lines. This
type of substation can change the transmission voltage to a sub-transmission voltage (69kV). The
converted voltage lines can provide a source for distribution substations. In some cases, power is
tapped from the line of -transmission line to utilize in an industrial capacity along the way. Or
else, the power will supply to a distribution substation.

 Underground Distribution Substation

Installation of a substation in urban centers requires large space, but generally, they don’t have a
place to install the substation. To overcome this problem, installing the substation underground
decreases requirement of space and the surface area can also be used for other constructions like
buildings, shopping malls, etc. The main concept of the underground substation is to offer the
best conventional substation by reducing the space occupied above land.

 Switchyard

The switchyard is the mediator among the transmission as well as generation, and equal voltage
can be maintained in the switchyard. The main purpose of this is to supply the generated energy
from the power plant at the particular level of voltage to the nearby transmission line or power
grid.

 11kv Substation

The main purpose of the 11kv substation is to gather the energy which is transmitted at high-
voltage from the producing station, then lessens the voltage to a suitable value for local
distribution & provides amenities for switching. This substation includes isolator, lightning
arrester, step-down transformer, CT metering, circuit breaker, and capacitor bank.

 220 kV Substation

Here, the 220kVA substation is the power-capability utilized by the step-down transformer in the
substation, and it illustrates the highest apparent power a step-down transformer can provide.
The received voltage level of this substation will be 220kV.

 132 kV Substation

The 132kV is the rating of the step-down transformer, which has a 132kV primary voltage.
Generally, these transformers are employed in transmission type substations where the voltage
has to be stepped-down to additional distribution. Similarly, some of the substations are
classified based on the nature of duties, service rendered, operating voltage, by importance and
design.

 The nature of duties-based substations are step-up, primary grid substation, step-down.
 The service rendered based substations are service rendered which includes a
transformer, switching and converting substations.
 The operating voltage-based substations are high voltage, extra high voltage, and ultra-
high voltage substations.
 The importance-based substations are grid and town substations.
 The design-based substations are indoor, outdoor, foundation mounted and pole mounted
substations.
 Transmission substation

A transmission substation connects two or more transmission lines.[2] The simplest case is
where all transmission lines have the same voltage. In such cases, substation contains high-
voltage switches that allow lines to be connected or isolated for fault clearance or maintenance.
A transmission station may have transformers to convert between two transmission voltages,
voltage control/power factor correction devices such as capacitors, reactors or static VAR
compensators and equipment such as phase shifting transformers to control power flow between
two adjacent power systems.

Transmission substations can range from simple to complex. A small "switching station" may be
little more than a bus plus some circuit breakers. The largest transmission substations can cover a
large area (several acres/hectares) with multiple voltage levels, many circuit breakers, and a large
amount of protection and control equipment (voltage and current transformers, relays and
SCADA systems). Modern substations may be implemented using international standards such
as IEC Standard 61850.

 Distribution substation

A distribution substation transfers power from the transmission system to the distribution system
of an area. It is uneconomical to directly connect electricity consumers to the main transmission
network, unless they use large amounts of power, so the distribution station reduces voltage to a
level suitable for local distribution.

The input for a distribution substation is typically at least two transmission or sub-transmission
lines. Input voltage may be, for example, 115 kV, or whatever is common in the area. The output
is a number of feeders. Distribution voltages are typically medium voltage, between 2.4 kV and
33 kV, depending on the size of the area served and the practices of the local utility. The feeders
run along streets overhead (or underground, in some cases) and power the distribution
transformers at or near the customer premises.
  Switching station

A switching station is a substation without transformers and operating only at a single voltage
level. Switching stations are sometimes used as collector and distribution stations. Sometimes
they are used for switching the current to back-up lines or for parallelizing circuits in case of
failure.

A switching station may also be known as a switchyard, and these are commonly located directly
adjacent to or nearby a power station. In this case the generators from the power station supply
their power into the yard onto the generator bus on one side of the yard, and the transmission
lines take their power from a Feeder Bus on the other side of the yard.

 Mobile substation

A mobile substation is a substation on wheels, containing a transformer, breakers and bus work
mounted on a self-contained semi-trailer, meant to be pulled by a truck. They are designed to be
compact for travel on public roads, and are used for temporary backup in times of natural
disaster or war. Mobile substations are usually rated much lower than permanent installations,
and may be built in several units to meet road travel limitations

METHODOLOGY FOR SUBSTATION WORKS

1. Substations Works

the works that genus power infra structure ltd will be carried out are the following ones: -

 Excavation and earthworks

 Ditch excavation for Cable Trenches, Earth Grid and Auxiliary Services
 Cable Trenches concreting, filling and compaction
 Pipe installation in ditch
 Foundations/concreting
 Formwork and stripping
 Brickworks
 Plumbing installation
 Air-conditioning installation
 Fire protection installation
 Electromechanical assembly
 Cable laying and connections
 Transformer assembly

2. Site Manager Works Definitions

 Site Manager is the person who is present during the works and manages this by appointment
or designation of the Construction Manager. The Site Manager will confirm creation of the
Protected Area in the installation, checking. Opening with an effective cut-off of all possible
sources of voltage. Blocking and signage of the cutting apparatus controls. Verification of the
absence of voltage. Earthing and short-circuiting to demarcate the Protected Area. To create
the Working Area, the Site Manager will perform the following

 Verify the absence of voltage in all the conductive parts which affect the Working
Area.
 Screening if the Safety distances are not complied with.
 Earthing and short-circuiting on both sides of all the phases which enter the place
where the work is being carried out, once the absence of voltage has been checked.
 Physical demarcation and signage of the area taking into account the minimum
distances that will be observed with the voltage elements, by placing signs, barricade
tapes, clearance gauge, etc.

3. Voltage Suppression:

1-.Open, with a visible cut, all sources of voltage, by means of switches and breakers which
ensure that no unforeseen closing of the source is possible.

2. Jamming or blocking if this is possible, of the cutting apparatus: - Mechanically: using safety
locks, locking pins, padlocks, etc. - Electrically: using fuses, breakers, etc. Signage of the
apparatus controls: using standardized signs and placing these on the activation controls of the
cutting devices with the words: “Operations prohibited, work in progress”.

3. Verifying the absence of voltage. In all the installation’s active element and as near as possible
to the work area. Using appropriate “voltage detectors”.To confirm the absence of voltage in
insulated cables or conductors which might be confused with others present in the working area,
use devices which act on the conductors such as: cable cutters, etc. Use of Personal Protection
Equipment appropriate for the work being carried out.

4. Earthing and short-circuiting of all possible sources of voltage.

5. Signage of the working area. Demarcate the working areas using tapes, fences, chains, etc.
Signal the cutting apparatus controls and the areas defined for performance of the work. Signs
which indicate “obstacles and hazardous areas” have yellow and black or red and white borders
at an angle of 45º. Those which indicate “work areas” are triangular in shape with a black
pictogram on a yellow background with black edges.

4- Machinery and Material Transport

Transport of Material Vehicles used to transport materials will comply exactly with the
provisions of the traffic code, paying particular attention to the following points: Materials will
be perfectly secured to the vehicle box or chassis, by means of straps and slings, to prevent them
from slipping or falling. They will not protrude from the box in excess of the legally stipulated
distance. If they do protrude this will be perfectly indicated and in no case they may protrude
transversally.

When an operation is performed by a number of workers, only one will be responsible for the
manoeuvre. Loading and unloading reels will be performed with the help of ropes and ramps,
rolling the reels on the two edges. No operative will stand in front of the reel while it is being
moved. If the reels are not going to be used, they will be lain down to prevent them from rolling,
and if they are supported on the edges, they will be perfectly secured on both sides.

Loading with mechanical resources Lifting loads with mechanical resources involves, among
others, risks due to the fall of heavy objects, becoming trapped or knocked, as a result of failures
in the crane or in the fastening elements. Electrical accidents can also occur as a result of direct
contacts or electric arcs. The following rules will therefore be complied with: -

 Prior analysis of the manoeuvre to be performed, location and movement of machinery

taking especially into account the safety distances and live elements.
 The machine will earthed and well stabilized on firm ground.
 The fastening elements to be used will be checked: slings, straps, hooks, shackles, etc.
checking their condition and that the work load is indicated and is appropriate for the
manoeuvre to be performed.
 The load will be secured so that it maintains a stable position, and all the slings support
equal loads.
 As far as possible placing the slings directly on pointed edges will be avoided.
 We will aim to use a type of securing that does not reduce the load on the slings.
 The Works Manager will perform a detailed follow-up of the manoeuvre, the hoisting
will be performed slowly and no people will be allowed to pass under or remain in the
load hoisting area, expect when the load is received.
 No loads which exceed those indicated in the machine load diagram will be hoisted. The
load limiter will not be cancelled or inoperable.
 In the event of a storm or strong winds (of around 60 km/h), the work with craneswill be
interrupted.
 The crane will never be left with the engines running or with a load.
 The hoisting of persons in cages or baskets not designed for this purpose is prohibited.

5.LAYING OUT WORKS

Climbing or accessing via areas with a steep slope will be avoided, unless properly attached to a
fall prevention system (lifeline, fall arrest device and safety harness). The entire work team will
use special anti-slip boots for avoiding falls down slopes and same-level falls. All inspection or
laying-out works at a height will be performed with a fall prevention system (lifeline, fall arrest
device and safety harness). Access to formwork areas or heights of factory structures and
constructions for inspections or data recording will be via the stipulated staircases or other
suitable access means, such as tubular structures (fixed ladders). Laying-out works may not be
performed on the structures until the edges and gaps are protected with the corresponding
railings or nets for covering the gaps. During laying-out works, persons will not remain in areas
with risk of falling objects. Work teams will be notified of the presence of persons and avoid
using tools until the area is clear. When hammering down pegs with the aid of long strike plates,
gloves and strike plates with hand guards will be used. It will be avoided the use of strike plates
with deformations in the impact area due to the risk of projection of steel particles to the face and
eyes. Safety glasses will be used during these operations.

6.Excavation & Earthworks

All affected services, whether water, gas or electricity, that may be present within the radius of
the excavation works will be perfectly located, arranging their re-routing or shut-down with the
corresponding supply company. If unexpected underground ducts or services are encountered,
works will stop immediately and an urgent notification will be sent to the Construction
Management. Works may be re-started when determined by the Construction Management.
Before starting the works, the work site will be inspected for possible cracks or earth
movements. Truck scoop loading operations will be directed by the supervisor. It is forbidden to
work or watch the works within the radius of action of the arm of an earth moving machine. In
general, in excavation works the necessary precautions will be taken to prevent collapses
according to the nature and condition of the land and the way of performing the works. If water
is present on site, it will be immediately removed to prevent ground alterations that may affect
the stability of the slopes. The excavation front made by machine may not exceed more than one
meter the maximum height of attack of the machine's arm. The front and vertical walls of an
excavation will always be inspected by the supervisor when starting or stopping the works,
marking the points that will be touched before starting or stopping the works.

7.Trench Excavation

Excavation earths will be kept away from the trench to prevent stones and rubble from falling
into the trenches. Particular care will be paid to any elements present near the work areas which
can have their support bases damaged by the excavation, such as trees, curbs, lampposts,
electricity posts, etc. When appropriate, brace or anchor these elements to prevent them from
falling. The entry of surface water into the trench will be avoided. Drainage of deep trenches will
be performed according to the solutions foreseen in the Technical Documentation and/or
requesting complementary Documentation from the Project Management. When the machine
will be placed above the area to excavate and at the edge of excavations, if the ground allows, a
retrodigger will be used or refining will be performed manually. If an unforeseen electrical line is
found, some of the following preventive measures will be adopted immediately. Stop excavation
works near the line. − Uncover the line manually without damaging it and exercising great care.
− Protect the line to prevent damaging it, prevent access of personnel to the area

and inform the supply company. − A supervisor of the supply company will be present in all
works performed near live lines. Works near gas conducts will be performed in a manner that
prevents breaking the conducts, with the means necessary to ensure that workers' lives are not in
danger in case of leaks. Machines or compression hammers may not be used under any
conditions for excavation near gas pipes in service. As a rule, if the location of the gas pipe is
perfectly known, excavations with machine or compression hammer will be stopped one meter
from the pipe containing gas. The rest of the excavation works will be performed by hand, using
shovels or hoes and not pickaxes if the ground allows. To remove earth less than 0.5 m. from the
gas pipe, the supply company will be asked to cut off supply and bleed the affected pipe
segment. The pipe will not be undermined until it has been suspended from elements calculated
specifically to prevent deformation and cracking of the pipe. No excavation earth or any other
materials will be accumulated next to the edge of the excavation. A distance of at least twice the
depth of the excavation at the corresponding edge will be observed, unless otherwise authorized
for each case by the Project Management. An inlet and outlet channel will be established for
material storage and clearing units. A work pace will be established that prevents accumulations.

8.Concreting, Filling & Compacting Trenches

In public roads in use, all machinery will be removed at the end of the work day, establishing a
place to park them. The materials, machinery, instruments and tools needed to carry out the work
will be placed in a location that minimizes their incidence on pedestrian and vehicle traffic, using
areas not normally used by these. They will be carefully ordered, fenced and signed, minimizing
the surface occupied and remaining only as long as needed for their use or inclusion in the work.
When visibility conditions advise so, workers will be given work clothes that ensure that they are
seen by drivers. The work team will be assigned a minimum separation between workers
according to the auxiliary means used to prevent collisions and interferences between them.
Workers will receive training on the correct use of the Personal Protective Equipment needed to
carry out their work. Workers handling rollers or compacters will be specialized in the use of
these machines and hold the corresponding accreditation. All vehicles will be revised
periodically, particularly regarding their pneumatic actuation systems, recording the revisions in
the maintenance book. Cutting of floor slabs will be performed with a wet line system that
prevents dust emission. If the pieces will be cut in a dry line, the operator will be placed upwind
to avoid inhaling dust produced while cutting. The operator will also use eye-protection goggles
and a dust mask with a mechanical filter adjusted to the eye-protection equipment.

9.Installation Of Ducts In Ditchs

When materials will be unloaded, first select an even storage place on which to place the tube
segments with the suitable protections preventing them from moving and therefore from falling.
If tubes are stacked, do so carefully to prevent a subsequent collapse of the stack. After preparing
the ground on which the tubes will be placed, transport the tubes parallel to the layout. The
measures described above will be observed during these operations. The tube will not be used as
a support point for entering and exiting the trench, even if it is completely immobilized. The
ladders provided for this purpose will be used. Walking on the tubes is forbidden. Handle the
various materials and auxiliary means used in the assembly properly to prevent injury.

10.Foundations & Concreting

The concrete mixer truck will always be parked inside the demarcated work area, in no case out
of the marked, signed and suitably demarcated areas. Before pouring concrete, the resistance and
stability of the formwork will be checked. When concrete will be poured directly from the truck
into a trench or a different level, place a safety block or place the truck at least 2 metres from the
edge to avoid overloads on the edge that may lead to collapse.

During approach manoeuvres, the concrete mixer trucks will remain more than 2 metres from the
excavation edge. Concrete truck movements in reverse gear will be directed by a single person to
avoid giving contradictory instructions. Take care when lowering the chute to avoid entrapment
of hands. When a concrete pump is used, a basket will be present at the worksite to collect the
ball used to clean the concrete pump pipe. If the pump pipe is jammed, release the pressure
before banging the pipe to find the jam. The concrete mixer will leave the work site with its
chute fully retracted. Protective rubber gloves will be used when working with concrete or
mortar. When a mechanical crane is used to pour the concrete, special attention will be paid to
the movement of the bucket with the concrete to prevent being hit by it. If an electric vibrator is
used, rubber gloves will be worn. Before starting the works, the work site will be inspected to
detect possible cracks or earth movements. Trenches will be checked at regular intervals
whenever they may receive pressure from nearby paths with vehicle traffic, and particularly if
there are nearby worksites using pneumatic hammers, vibration compacters or if earth moving
machinery passes nearby. When the depth of the trench is two meters or more, the upper edges
will be protected with a regulation railing placed at least 2 metres from the edge. wooden
plankways of 60 cm wide will be installed with 90 cm high solid railings and protection to
prevent persons from passing or sliding under the railings or objects falling on persons. When
pouring concrete, observe the formwork and reinforce any weak points. In case of failure, it is
best to stop pouring and resume it only when the formwork performance is correct.

11.Works with Steel Reinforcement Bars

A space will be provided in the worksite for classified storage of rebar rolls, near the
reinforcement assembly location. Rebar roll packages will be stored horizontally on wooden
sleepers, layer by layer, avoiding stack heights above 1.50 metres. Package points will be
protected with caps that will not be removed until their final assembly in the worksite. The rebar
workshop will be located such that the crane has access to it without the hanging loads passing
over the assembly workers. When lifting the bars, avoid passing the iron packages over the
workers. Overhead transport of rebar packages with the crane will be performed hanging the load
from separated points by slings. Assembled reinforcing bars will be stored in the assigned places
separated from the place of assembly.

Iron and steel waste or excess material will be collected and stored in the specified place for
subsequent loading and transportation to the dump. Brads, wires and rebar waste around the
worksite will be swept daily. Mounted reinforcing bars will be carried to the location hung from
the crane hook by slings attaching it to two separated points to prevent unwanted deformations
and displacements. Overhead transportation of pillars in vertical position is forbidden. The pillars
will be hung from two points by slings to a point near their final location and deposited on the
ground. Vertical transportation will only be allowed for their exact positioning on site.

12. Masonry Works

The condition of the auxiliary means used in the work will be checked at the start of each day.
The worksites will be maintained in orderly and clean conditions, free of rubble and garbage
mainly, by removing them with hoppers or carrying them to areas designated as dumps.
Throwing rubble directly out of façade openings or gaps is forbidden. Transit surfaces will be
free of obstacles, whether materials, tools or rubble, which may lead to risk of same-level falls.
Work sites will be properly lit. Otherwise, additional lighting will be provided with a protection
mesh and 24V safety power supply. Ceramic material will be lifted to the floors without breaking
the straps supplied with them by the manufacturer. Do not handle them with the body or hands,
only with ropes. Loose material will be stacked in an orderly inside carrying platforms, ensuring
that the pieces cannot fall.

Special care will be observed when using cutting tools. However, it is recommended to follow
the instructions provided in their specific procedure. The worksite will be kept clean and marked,
as will be the glass and ceramic etc. cutting areas. Special care will be taken when working with
marble to prevent crushing of limbs or organs. All work with a risk of flying particles will
require the use of safety glasses with clear, tempered, curved and optically neutral glass, a sturdy
rim, universal bridge and perforated plastic side protections. When necessary, the glass will be
graduated and protected by another superimposed glass. Work benches will be kept clean and in
good condition, avoiding chipping or splinters during the work. The safety protection of
apertures in the floor structures will be replaced immediately once plumbing work for vertical
conduits has been completed in order to prevent the risk of falls. The operator performing
plumbing installations will wear a safety belt at all times. The work area will be kept clear of off-
cuts and debris. These will be cleared as work progresses, piled in a proper location until
disposed of down the chutes. Welding and soldering with lead is prohibited in enclosed spaces.
Whenever performing welding or soldering work with lead, establish a current of air to ensure
proper ventilation and prevent exposure to toxic fumes. Electrical lighting will be provided using
portable lamps, properly grounded, with insulated handles and protective cage over the bulb. For
welding and soldering work, operators will follow the instructions provided in the corresponding
procedures. Plumbing fixtures will be carried on the will er, separating broken fixtures and their
fragments carefully. The installation of plumbing fixtures will be performed by at least three
persons: two to move the piece and a third to position it in its proper position to prevent falls or
trapped fingers.

14. Installation Of Air Conditioning Systems

Materials will be piled in a previously designated location. Equipment and materials will be
hoisted with the help of resistant balancing poles using with the crane hook. Materials will be
positioned on the ground which has been previously prepared using pallets or boards to distribute
the weight. From here the materials will be transported to their storage area or where they are to
be installed.

15. Installation Of Fire Protection Systems

Before beginning the project, the construction method, type of scaffolding to be used and the
transit routes of the site will all be approved by the Project Management. A study will be made
for the preparation of the work areas in order to determine the most appropriate installation of
scaffolding and ladders in transit areas and forms of access.

Work and transit areas will be kept clean, neat and well lighted at all times. Equipment and
machinery will be kept in perfect condition, using the most appropriate equipment and tools for
each task. Equipment will only be used by personnel who are fully qualified and authorized by
the project supervisor.

16. Installation Of The Transformer

This work is divided into the following sequences: Unloading Levelling and securing to the base.
Assembly, cabling and connection. This first sequence of the work involves the risk of falling
objects during handling, impacts against stationary objects and overexertion. If the unloading is
being performed using a crane, verify that the load is within the maximum permitted load
weight. Ensure that the hook has a safety latch and that the stirrups are correctly positioned and
can support the load weight. Operators performing this task will wear safety gloves and boots.
Loads will always be suspended at four points as the hooks are sometimes welded rather than
connected to the frame. These welded joints are not always secure and suspending loads from
less than four points can cause joints to break. Once the equipment has been unloaded, it will be
moved to its place of installation, depending on the distance, by auxiliary mechanical equipment,
hand carts or similar. The equipment will never be dragged across the floor regardless of how
smooth as this can cause injuries to operators (overexertion), and also damage both the floor and
the equipment itself. Levelling and securing to the base Once the equipment is positioned on its
base, it will be levelled using a spirit level or plumb line. Once level, proceed with the fixing of
the equipment to the base either using screws or welding.

17. Cable Spool Storage And Installation.

Cable spools will be stored in closed locations, especially when being stored for long periods of
time, in which case they will be covered with tarps or other means. Spools of LA conductor can
be stored outdoors providing the free ends are properly secured and retained. Spool of insulated
conductors can be stored outdoors providing the free ends are properly protected from the
elements (removable caps, staples or clamps, etc.).

Spools will be stored on paved surfaces, free of mud or dust even when outdoors. The protective
slats will remain on the spools until their moment of use. Spools will be stored in vertical
position, installing wedges at the base of the spool or using similar means to guarantee stability.
Spools will be stored with a minimum gap of 7.5 cm between the spools.7.5 cm (min) Only those
spools with a protective cover can be piled face to face. The bottom spools will be properly
footed or secured with wedges to ensure stability.

18. Cable Laying And Connections

Cable laying operation can be divided into the following sequences

I. Selection of the work area.

II. Transport of spools and equipment.
III. Preparation for laying cables.
IV. Laying cables.
V. Termination of cable laying.
I. Selection of the work area

Before beginning the work it is necessary to determine the position of the cable spools and
the ideal location for the lifting jacks. This area will provide a solid and firm surface. If this
is not possible, the jacks will be positioned on boards to increase the support surface,
guaranteeing solidity and stability. The area where the spools are stored will be close to the
work area and not pose an obstacle to work or transit areas. Both areas will be sign-posted
appropriately.

II. Transport of spools and equipment

Cable spools will be transported by truck and loaded and unloaded using a crane. The risks
inherent in the phase of the installation are impacts and contusions, injuries and scrapes when
carrying out these operations. To reduce these risks, operators will proceed as indicated below: o
All clamps, stirrups and axes to be used will be in good condition and appropriate for the load
weight to be transported. The spools will be secured with wedges or footings inside the bed of
the truck during transport. Personnel will not remain in the bed during transport’s lifting jacks
will be appropriate for the load weight of the spools and will be checked and lubricated in the
workshop before being taken to the site.

If the operation requires the use of electric winches, these will be checked, verifying they are in
perfect mechanical and electrical condition before leaving the workshop. Operators will ensure
that gears, pinions, traction chain, etc, all function correctly, the steel cable rides on and off the
drum properly. This will be lubricated before being taken to the site. The levels of pinion fluid
and the ground connection will also be checked. The jacks, axes, winches and other tools and
equipment will be transported to the site with the cable spools. The crane hook will be equipped
with a safety latch.

III. Preparation for laying cables

The risks inherent in the phase of the installation are elevated falls, impacts and/or
contusions, injuries, entrapments by the slings and/or cables, etc. Personnel will use the
appropriate personal safety equipment at all times, including hard hats, safety gloves and
safety belts where necessary. When laying a cable on a cable tray the lift jacks will be
positioned under the trays where the cables will enter, in order that there is an inclination of
some 120º between the first roller of the tray and the cable spool. The spool will then be
mounted on the jacks, if very heavy a crane or hoist will be used, raising the spool until the
steel axle fits the axle holders of the jacks. * Once the spool is in position, the slats protecting
the cable will be removed one by one with the nails belt back to prevent possible injuries.
Once the spools are uncovered, the slats will be cleared from the area. The winch will be
installed at the other end of the installation. If this is very long and presents angles or corners,
additional winches will be positioned to pick up the slack which will then be recovered by
the final winch. Only for power cables, m.t. cables and 380 v.- 150 cm. The steel cable
winches will be fixed to the structure using shackles and clamps, verifying they are secure.
Rollers will be installed the length of the trays, spaced depending on the diameter and weight
of the cable. Then, releasing the pinions of the last winch, the steel cable is pulled, laid
across the rollers until the end reaches the spool. The electrical cable to be laid will be
unrolled a few turns and when the end reaches the floor, the corresponding cable lead will be
attached and properly secured to ensure it does not come free. If the cable is damaged during
laying it will be replaced immediately. Once the cable lead is attached to the cable to be laid,
this will be attached to the steel cable of the winch using clamps or shackles.

IV. Cable laying

Special attention will be paid in this phase of the operation to prevent mistakes or
uncontrolled manoeuvres, contusions or impacts. Workers performing these operations will
 synchronize their actions carefully. Mistakes or uncontrolled manoeuvres can cause serious
accidents and damage the cable.

V. Termination of the installation

Once the laying of the cable is complete, the winches, spools and other tools and equipment will
be collected, leaving the site clear. Finally, the safety signage will be removed. Connection
When proceeding with the connection of the installation, it will be determined if the connection
will be performed with or without voltage. If the cables to be connected and the equipment are
disconnected, operators will proceed in the following manner: The first action is to verify the
lack of voltage in the cables to be connected. Equally, operators will verify that the equipment is
also without power if this has an alternative power source.

Once the absence of voltage in the work area has been verified the connection will be made
using the appropriate tools.

If the equipment to be connected is in tension, operators will request the disconnection of the
same. If the disconnection request is granted, work will not begin until operators have verified
that the equipment is disconnected from the power source and that accidental reconnection is
impossible.

19. Earth Grid

When laying the Grid, the same prevention measures will be observed as the general cable
laying. For shunting the main network and take it to the different equipments, the Cadwell
welding procedure will be followed. To this end, operators will use working gloves and their
personal wear, and follow the sequences below:

1. Check that the moulds are in a clean and unworn condition. Each mould is intended for a
given number of weldings. When this number is exceeded, they will not be used again, since the
holes through which cables have to tightly pass may become deformed and the melted material
may flow out at high temperature causing serious burns and, therefore, to a faulty welding work.

2. The welding material contained in the cone of the mould will not be ignited with matches or
burning paper. When using matches, it is necessary to approach one hand to the ignition point
and it may get burnt. When using burning paper, ashes from the paper together with the material
may cause dirty weldings, and this becomes faulty. Always use the lighter that comes with the
mould. The connection of these lines to the equipments is made by attaching terminals to the
cable ends, which are fixed to plates previously secured to the equipments by means of a screw
bolt of the appropriate dimensions.

20. Permanent Electrical System.

The warehouse to store electric material will be located in the place designated for that purpose.
When openinig and closing wall chases, the order and cleanliness at the worksite will be
carefully taken into account. The assembly of electrical devices (magnetothermic switches,
breakers, etc.) will be always performed by qualified staff. For the illumination by means of
portable lamps, watertight lamp holders will be used with insulating handle and bulb protection
grid, fed by 24 volts. Connecting wires to the electrical site distribution unit is not allowed
without using male-female plugs. Step ladders with anti-slip footings and a chain to prevent
overextending will be used. For the correct use of ladders, it is recommended to follow the safety
instructions included in the relevant procedures. It is forbidden to create scaffoldings using step
ladders by way of sawhorses. For using scaffoldings, it is recommended to follow the safety
instructions included in the relevant procedures.

21.Electric Welding Works

Working areas will be always clean and tidy to avoid tripping and stepping on pointed objects.
Metal beams will be secured with slings at two points, so that the upper angle at the mooring ring
level formed by the two cables of the sling is 90º or less, in order to avoid risks of stress of the
auxiliary means. For hoisting metal beams (frames), ropes will be used until their “presentation”,
never directly with hands, in order to avoid pushing, cuts and entrapments. “Presented” beams
and pillars will be secured and blocked using fastening spindles, lip blocks, slings, the crane
hook, etc., until finishing the “tack welding” in order to avoid unstable situations. This work will
not be raised to a higher level until having finished the weld bead of tack welding level, in order
to avoid unstable situations in the structure. Metal pillars will be vertically hoisted and being
guided by means of ropes, never with hands. Plumbing and stippling will be immediately carried
out. Horizontal fireproof nets will be arranged between the centre lines being mounted, in order
to avoid risks of falling from a height. Arc lamp radiation is harmful to health. Always use
welding hood or hand mask when welding. Do not look directly at the arc lamp. The intensity of
light may cause serious eye problems. The weld bead will not be chipped without eye protection.
The removed chips of scale may cause serious eye injuries. Do not touch recently welded parts;
contrary to its appearance, they may be at temperatures that may cause serious burns. Always
weld in well-ventilated places to avoid intoxication or asphyxia. Before starting to weld, check
that no people are around the vertical of your workstation in order to prevent them from getting
unintentionally burnt.

22.Works At Height

During works, workers will be permanently secured, all the time that the work takes. They will
use a work rope with two anchor points for these works.Works at a height can be only performed
with the help of equipment intended for that purpose or using collective protection equipments,
such as railings, platforms or safety nets. If this is not possible due to the nature of works, safety
access means with anchoring or any other similar protection means will be provided. Order and
cleanliness in the working area. The manual handling of loads during these works will be in
accordance with the R.D. 487/97 on manual handling of loads. When performing these works
(lifting, descending and shifts), workers will be permanently secured. The use of a two-anchor
work rope is obligatory. The condition of the means to be used will be checked, rejecting those
not offering safety for their use. In a stop while ascending/descending or stops made to work, the
rope with two anchor points will be always secured before releasing the life system. These ropes
will be anchored, whenever possible, above your head in order to have a perfect safety guarantee.
If no anchoring can be used above head, they will be anchored at the highest points, avoiding
anchoring below the waist.

The surfaces of working ramps, ladders and platforms will be made of non-slippery materials or
will be provided with anti-slip elements. Special attention will be paid not to load the just-built
elements with materials, devices or, in general, any other load that may cause their collapse.
Operators working in the assembly of metal or concrete structures, or on site elements that,
because of their high location or any other circumstances, involve a risk of serious fall, will be
equipped with safety harness, duly attached to firmly secured points. Railings being removed or
holes being opened for introducing equipment, etc., will be perfectly watched and signalled
during the operation, replacing the corresponding protections right after finishing it. To avoid
falling objects: -

 Coordinate works so that they do not overlap.

 If works in the same vertical line are required, install the relevant protections (nets, roofs,
etc.)
 Demarcate and install signs in areas with risk of falling objects.
 Install signs and monitor the area where works performing with suspended loads. Loads
will be handled from outside the load influence area. This area can be only entered when
loads are practically down.

23. EQUIPMENT, MACHINERY AND TOOLS TRUCK CRANE

All hoisting and transportation equipment employed in the project will meet the appropriate
general standards of construction, stability and resistance and will be equipped with safety
mechanisms or systems to prevent: The fall or sudden swinging of a load due to the malfunction
of a machine, hoisting device or transport equipment or the breakage of cables or chains, etc.The
fall of persons or materials from the transport receptacles provided for this purpose. The
accidental or unexpected start-up. All types of accidents which may affect the operators working
with this equipment or in their vicinity.

All vehicles and machinery used for handling materials will be: Well designed and constructed,
taking ergonomic principles into account wherever possible Equipped with a certified fire
extinguisher, regularly inspected and serviced, in the case of fire. Maintained in good working
order. Used correctly. Drivers and personnel responsible for vehicles and equipment used to
handle materials will receive the appropriate training. Preventive Measures will be taken to
prevent vehicles, earth moving machinery or handling equipment from falling into excavations
or water. The ideal location for the crane will be considered before it is positioned. The
maximum loads permitted for the various degrees of inclination will be indicated. Operators will
only ascend or descend from the crane when the truck is stopped. If contact is made with
electrical power cables, do not leave the truck until contact is broken and you are well clear of
the place of contact. Jump clear without touching the truck and the ground at the same time.
When hoisting the cage, verify that it is properly connected and secured to the hook; raise slowly
and ensure there is no danger of overturning; for this, only loads which are completely free can
be hoisted, nor exceed the maximum load limit of the crane. Never leave the crane when a load is
suspended. The crane operating radius will remain clear of personnel at all times.

24.Hoisting Equipment

A rope is a textile element that will have a minimum diameter of 4 millimeters consisting of
twisted or braided fibres with or without core. Ropes used for hoisting or carrying loads will
have a minimum safety factor of 10. Do not drag rope over rough surfaces or on the ground, sand
or against unprotected angles or pointed edges. All hemp ropes which are returned to storage
after use will be inspected their entire length. Any knots in the rope will be undone, as they
conserve humidity, and the rope will be washed clean of any stains. When fully dry, the rope will
be checked for possible deterioration: cuts, fraying, acid attacks, etc. Ropes will be stored in a
dark, dry and well-ventilated location, free of fumes and taking all possible precautions against
rats or other rodents.

Rope will not be in direct contact with the ground but will be isolated using stakes or pallets
which allow air to flow under the coils. Synthetic rope will be stored in temperatures below 60º.
Avoid unnecessary exposure to light. Avoid contact with oils, acids or corrosive products. Ropes
used in fall arrest systems, which have stopped the fall of worker, will not be used again, or at
least not for this purpose. Ropes will be checked their entire length before use. Avoid using ropes
against pointed angles. If ropes will be used in the vicinity of flame, they will be protected by a
leather sleeve, for example. Ropes used to support loads, or work with traction will be free of
knots. Knots reduce the strength of the rope. It is essential that ropes be protected from abrasion,
avoiding all contact with pointed edges or corners and using a thimble in the rings of the slings.
Pressure against pointed edges can cause cuts in the fibres which can dangerously reduce the
strength of the rope. To prevent this, a flexible material (cardboard, fabric, etc) will be placed
between the rope and the pointed edges. Cables A strand is constituted of various steel wire laid
in a helix of one or various layers.

A cable is constituted of one or various strands laid in a helix of one or various layers around a
core. Cables will have the construction and size appropriate for the purposes for which they will
be used. Cables will have a safety factor of no less than 6. Cable eyes and connection for hooks,
rings and clips will be fitted with sufficiently resistant thimbles. Cables will be free of knots,
permanent twists or other defects. Cables will be inspected periodically for broken wires. Cables
will be replaced if showing more than 10% of broken wires, counting the length of two sections
of the cable separated by a distance inferior to 8 times the cable diameter. Cables used to lift or
support loads directly will not have any joints at the ends (the only joints or connection permitted
are those which are designed to be modified according to operational needs). The use of cables
and attachment devices and equipment will be selected in order to guarantee an appropriate level
of safety. The diameter of cable drum hoists will not be inferior to 20 times that of the cable,
providing it is also 300 times the diameter of the largest wire. Follow manufacturer’s
recommendations for hoisting equipment with regards to the type of cable to be used to avoid
premature wear and even breakage. Never used cables other than those recommended. The ends

Breakage of a strand Abnormal and localized reduction in diameter. Existence of knots. When
the reduction in diameter of the cable at any point reaches 10% for strand cables or 3% for solid
cables. When the number of visibly broken wires reaches 20% of the total number of wires in the
cable in a length equal to twice the section of cable. ∗ When the reduction in a section of a
strand, measured in a section of cable, reaches 40% of the total section of the strand. Chains
Chains will be made of steel or forged steel. Chains will have a safety factor of at least five for
the nominal maximum load weight. The rings, hooks, links or bands fitted at the ends will be of
the same material as the chains to which they are attached. All chains will be inspected before
being put in service. When the links suffer excessive deterioration or has been belt or cracked, it
will be cut and replaced immediately. Chains will be free of knots or twists. Chains will be rolled
on grooved drums, axes or pulleys that allow the chain to be rolled without twisting.

Chains will be handled with care: avoid dragging them on the ground or leaving them on the
ground as they are exposed to the effect of dirt, dust, humidity and chemical agents in addition to
the mechanical deterioration which can occur. Chains used to carry loads in hoisting equipment
will be properly lubricated to prevent corrosion which may reduce their strength and useful life.
Hooks Hooks will be made of steel or forged steel. These will be equipped with latches or other
safety devices to prevent loads from slipping free.

Slings Special attention will be paid to the strength of slings. There are numerous causes for
strength reduction: Deterioration due to usage. Knots, which reduce strength by 30 to 50%. The
welds of the end rings or eyes, even when expertly performed, reduce strength by 15 to 20%.
Cable clips, even when used correctly and in sufficient number. Connections made in this way
reduce the strength of the sling by approximately 20%. Hooks of the hoisting equipment will
never be positioned on welds or points joined using cable clips or joints. The connections or
joints will be positioned on free areas working only with traction. The straps of two slings will
never cross over one another on the hook, as in this case one of the cables is compressed by the
other.

The lead band will be in perfect condition at all times. ∗ At least four cable clips will be used,
sitting on the side of the cable where the force is applied. The same number will be fitted at each
side of the centre of the joint. ∗ Any chain with a link whose diameter has been reduced by 5%
will be replaced. ∗ A chain link will never be replaced by a pin or a steel wire ligature, etc. ∗ A
link will never be welded in a forge or with a torch. ∗ The chains used in slings will be
calibrated, with ends fitted is rings or hooks. ∗ The chains used in the slings will not have any
links which are corroded, bent, crushed, opened or dented. Chains will be periodically checked
link by link. ∗ The chains of the slings will not be subject to a load superior to one fifth of their
breakage weight. If this figure is not known, it can be calculated 2 approximately, using the
formula: f(in kg.) = 6 x d (diameter in mm.)

25.Lectric Cement Mixer

The machine will be installed on level ground, avoiding transit areas and the proximity of the
edges of excavations or trenches. The ground will be properly drained or a platform will be used
to avoid wet or muddy ground. Special attention will be paid to the installation of the controls.
The start and stop buttons will be far enough apart to prevent them being confused when used.
The stop button will be distinguished from the others by being on the exterior, far from the drive
belt and painted red. Before start-up, the operator will verify that all the safety devices and
systems are installed and in good condition (drive belt and pulley covers, the ground, condition
of the cables, levers, tilt lock and other accessories Power cables will be positioned off the
ground where possible. If not, these will be properly protected and sign posted.

The electrical installations will include a ground connected to the circuit breaker. All cables,
connections, plugs, etc, will be in good condition. The machine will be kept clean, especially the
mixing drum. Cleaning will performed with the power disconnected.

Electrical power cables will be disconnected before performing any maintenance work to prevent
accidental start-up of the machine. The operator will take extra precautions when approaching
moving parts. The drum will movements.

When moving the cement mixer with a crane, appropriate hoisting equipment will be connected
at four secure points will be used. It is prohibited to clean or remove encrustations from the drum
when in motion. A platform will be installed around the machine to prevent slipping. Do not
handle or remove safety protections and shields from the machine. HYDRAULIC JACK For
single piston jacks, the hose will be inspected before every use. If damaged, this can cause
serious accidents. The hose will be protected during lifting to avoid damage from falling
materials, etc. Hydraulic jacks can only be used vertically; working horizontally can lead to
pump malfunction due to a loss of fluid. For work in horizontal positions, single piston jacks will
be used. The maximum piston extension will be noted, trying not to pass 2/3 of its length; never
reach the limit of the piston as this can lead to deterioration of the O rings.

26.ELECTRIC GENERATOR
Generators will be installed in a manner that they are inaccessible to unauthorised and
unqualified personnel. The location of installation will be well ventilated to prevent the creation
of a toxic or explosive atmosphere. The neutral will be grounded at source, with a resistance of
not more than 20 OHMS. The generator will be grounded with a connection independent of the
above, except in the case where it is equipped with insulation protection or reinforcement. The
generator will power a general electrical system which, in addition to normal installations for use
and protective elements, will include: -

When not being used, the flame of the torch will be pointed into open air or towards inflammable
surfaces. When working in enclosed spaces, appropriate ventilation will be provided. Equipment
producing a flame will only be used in areas free of obstacles. Machines or equipment powered
by thermal energy or combustion engines will only be used outdoors or in well-ventilated areas
in order to prevent the concentration of carbon monoxide. Gas-powered equipment will always
be kept in perfect working condition, periodically cleaning the gauges, fuel lines, ignition or
sparking elements, etc. Equipment will be refuelled when the motor is off to prevent the risk of
fire due to gasoline fumes. Given the level of noise produced by internal combustion engines,
hearing protection will be worn by operators when handling this type of equipment. It is essential
that the following tasks be performed using pneumatic tools or machinery: Purging the air
conduits and hoses. Verification of the condition of the flexible hoses and the nozzle couplings.
Examination of the position of the flexible hoses (there are not loops, elbows or bends which
impede the flow of air). Compressed air hoses will be positioned where they do not pose an
obstacle or can be damaged by vehicles.

Operators will never put all their body weight on the pneumatic equipment as this may slip and
cause a fall against the surface being worked on. After use, the following conditions will be
taken into account: Shut off the air feed valve. Open the air valve on the machine to purge the
circuit. Disconnect the machine. The end of the air hose of hydraulic equipment will be secured
by a small chain to prevent sudden decompression. The equipment will be positioned on a level
and stable surface.

Loose clothing will not be worn as they pose a risk of entanglements and entrapments. Do not tilt
tools to enlarge holes or expand apertures. The safety guards of portable saws will be in place at
all times. When working in damp or humid locations, the necessary safety measures will be
taken, including wearing insulated gloves, using wooden ladders and supports, safety
transformers, etc. Safety glasses will be worn when cutting, drilling, grinding, etc. using
electrical power tools. The condition and structure of the teeth of the disk will be checked. The
work area will be free of sawdust and shavings to prevent fires. Ensure there are no nails in the
material being cut. Portable drill Before use, the operator will check that all electrical
connections, double insulated housing and circuit breaker are in good condition to prevent the
risk of electrocution. In this case, small jobs can be conveniently performed on workbenches
with the electrical drill properly secured to the bench. Drill bits for the power drill will be
selected with care. If the bit is too fragile, it can break before beginning the work if the operator
applies too much force or has not prepared the bit properly. The point to be drilled will be
predrilled beforehand. The position of the drill with regard to the surface to be drilled is very
important as the drill bit is very fragile and any movement in direction or lateral pressure may
cause it to break.

27.Hand Tools

Hand tools will be manufactured from quality materials, especially those used for impacts,
which will be of carefully selected steel, strong enough to withstand impacts without deforming
or forming edges on the heads, but without splintering or breaking. Handles will be of smooth
hard wood without splinters or pointed corners. They will be perfectly inserted. Both tools and
their handles will have the form, weight and size appropriate for the work to be performed. Tools
presenting the following defects will not be used: ∗ Flattened heads with cracks or chips. ∗
Handles which are scratched or wrapped in wire. ∗ Blunted or poorly sharpened edges. The area
presenting special risks (the presence of flammable gases, volatile liquids, etc) will require the
use of tools manufactured with materials which do not produce sparks on impact. Work with
electrical installations will be performed with properly insulated tools. The appropriate tool will
be used for each type of job.

Tools will be stored in a manner that they can be positioned correctly, lost tools can be identified
quickly and are protected against deterioration due to impacts and falls. Tools will be easily
accessible without danger of cuts from sharp edges. Tools will not be left on or behind moving
machine parts. Protect cutting edges when not in use. Disorder in the work area makes repair
work difficult and leads to the inappropriate use of tools. Never throw tools. Works will hand
tools to each other. The user will be responsible to receive, care for and maintain tools in good
condition. Ball pane hammers The hammer will have a handle, well fastened with a wedge,
which is appropriate for the type of head used. The wedge will be of steel or iron and will press
the wood against the sides of the eye where the handle is introduced. If the wedge is introduced
at a slant, the pressure will be on both the longer and shorter sides of the eye. This will not only
prevent the formation of burrs in the groove and damage to the screwdriver head but will also
reduce the force required and improve the grip of the screwdriver. If the sides of the head are
well sharpened, these will be almost parallel. Pieces will never be held in the palm of the hand
when screwing or unscrewing. If the screwdriver slips this can result in a serious injury. The
piece will be securely held on a stable surface. Do not force screws which are too tight using
pliers or pincers. Use a lubricant instead.

The wrench will always be fitted perpendicularly to the bolt or nut. If it is at an angle it will not
fit properly and may slip easily. As a general rule, wrenches will be pulled rather than pushed. If
it slips suddenly the operator may suffer an injury. If the wrench will be pushed, the operator will
keep their hand open to avoid knuckle injuries. Never use handle extensions for wrenches such
as lengths of pipe, other wrenches, etc. Adjustable spanner Two precautions will be taken when
applying force to these wrenches, either when loosening a bolt or when tightening a nut or bolt: ∗
Position the wrench on the bolt in order that force is applied to the side of the wrench which is
fixed. The force will thus push the moving jaw against the bolt. ∗ After fitting the wrench to the
bolt, tighten the screw or wheel to improve the grip. Wrenches will be kept clean by applying a
solvent or gasoline periodically. The screw or wheel and the moving parts of the wrench will be
lubricated. Pipe wrenches Pipe wrenches, both straight and chain wrenches, will have their jaws
sharp and clean to avoid slipping, always working with traction. The screw adjustment of the
wrench will be checked periodically and will be replaced if cracked. These wrenches will not be
used on nuts, bolts, valves or other elements of tin, copper or other soft materials as they will be
crushed or deformed. Best results are obtained in gripping round objects in the centre of the
wrench jaws. Pipe wrenches will be positioned on the pipe only when they have been adjusted to
the proper size and are ready to apply force.

Files used for wood are called rasps and their teeth are triangular in shape. It is important to
choose the correct type of file to avoid injuries and to extend the life of the tool. When a file
become dull, the surface will be cleaned with a file card, never banging the tool against a metal
object. Files will never be used as a lever, chisel or any other type of tool. Files will never be
used without a handle or when it is cracked or chipped. When applying force, the end of the file
can stab into the hand or if the handle is defective, cause injuries. The handle will be fitted with a
ring or to prevent the handle from cracking or opening. The handle will be of an appropriate size
with a proper sized hole at one end. Files will be used by firmly holding the handle in one hand
and using the thumb and forefinger of the other to guide the point. When small pieces are being
worked on, these will be firmly secured using a screw or bench vise. Files will be stored in a
cloth or dry paper to prevent oxidation, keeping them clean and free of oils or grease. Metal saws
Saws consist of two parts, the frame and the blade. The blade will be fixed correctly to prevent
bending and possible breakage. The blade will be attached with the teeth pointing forward
towards the front of the frame. Force will be applied only in the forward direction, lifting the
blade slightly on the return.

28. Auxiliary Equipment Wooden Ladders

Wooden ladders will be used for electrical work, together with ladders made of polyester or fibre
glass. Wooden ladders are made up of two side members of a single piece, without defects or
knots which may reduce safety. Rungs will be joined rather than nailed. Ladders will be
protected from the elements with varnish, transparent in order not to disguise any possible
defects. The use of painted ladders is prohibited as defects are more difficult to detect.

General Before using a ladder, verify it is in good condition rejecting those which do not
guarantee complete safety. The side members will be checked to ensure they are of a single
piece, without joints, that there are no missing, loose or broken rungs, that none have been
replaced with bars and that there are no protruding nails. Before climbing the ladder, check that
the safety footings are free of mud, grease, or an other substance which may cause slipping.
Ladders will be ascended and descended frontally, that is, directly facing the ladder.

Ladders will have a length which surpasses the top support point or surface to be reached by 1
meter. The maximum length of ladders will not exceed 5 meters without an intermediate support,
in which case length can reach 7 meters. For greater heights special ladders or work platforms
will be used. Two ladders will not be joined together. If it is necessary to use a ladder in the
proximity of doors and hallways, leave the door open in order for the ladder to be visible and to
prevent impacts from the door against the ladder. Ladders will never be positioned on top of
moving mechanisms or bare electrical conductors

29.Step Ladders

Step ladders will be equipped with safety stop at their top hinge. Step ladders will be equipped
with a safety chain or brace at mid height to limit the aperture of the ladder. Step ladders will
always be used as designed, that is, with both sides opened for maximum safety. Step ladders
will never be used as horses to support work platforms. Stepladders will be positioned with their
legs extended to their maximum for maximum safety. Step ladders will not be used if the work
position requires the operator to place both feet on the top three rungs. Step ladders will only be
used when positioned on horizontal and stable surfaces.

30.Scaffolds On Sawhorses

All scaffolding will meet the following general safety conditions:

The elements and joints of the various pieces constituting the scaffolding will fit together
perfectly, ensuring proper stability and strength.

Scaffolding will be assembled and braced properly in order to ensure stability and allowing
operators to work with the maximum safety conditions. It is strictly prohibited to used boxes or
drums, etc, as provisional scaffolding. Debris, materials or tools will not be thrown directly from
the scaffolding. An appropriate system will be used to remove or unload this material. Sawhorses
will be positioned on perfectly level ground to avoid the risk of working on an incline. Wooden
sawhorses will be in perfect condition, firmly joined and without wobbling, deformation or
damage of any kind to avoid the risk of collapse, sudden breakage or swaying.

Sawhorses will not be positioned more than 2.5 meters apart to avoid excessive spans which can
increase the risk of swaying or shaking. Scaffolding will be assembled using a minimum of two
sawhorses. It is expressly prohibited to substitute sawhorses for boxes, barrels, piled materials,
etc. Only that material which is strictly necessary will be placed on the scaffolding and
positioned uniformly across the work surface to avoid overloads which may reduce the resistance
of the boards. Folding sawhorses with metal hinges will be equipped with safety chains to limit
the maxim aperture of the horses in order to guarantee compete stability.
31.TUBULAR SCAFFOLDING

All scaffolding will meet the following general safety conditions: ∗ The elements and joints of
the various pieces constituting the scaffolding will fit together perfectly, ensuring proper stability
and strength. ∗ Scaffolding will be assembled and braced properly in order to ensure stability and
allowing operators to work with the maximum safety conditions. A plan will be established for
the assembly, use and disassembly of the scaffold including a calculation of its strength and
stability made by fully qualified personnel. When the scaffolding being used has a “CE”
certification, this plan can be substituted by the operating instructions provided by the
manufacturer or supplier. Scaffolds will be assembled, disassembled, modified or inspected
under the supervision of qualified professional, fully trained in the use of this equipment and
performed by personnel who have received the appropriate and specific training necessary for
these types of operations.

Scaffolding will be assembly on wooden or metal footings sufficiently strong and braced to
guarantee the stability of the scaffolding. The scaffolding will be supported with a sufficient
number of diagonal braces to ensure that the structure retains its original rectangular form.
During the assembly and disassembly operations, the pipes of the scaffolding will be hoisted
using ropes knotted securely. Operators will wear a safety harness attached to secure points
independent of the scaffolding or to a lifeline. Scaffolding will be positioned a safe distance from
electrical power lines or installations to prevent contact with live elements. The following
specification will be taken into account during the assembly of tubular scaffolding:

 A new level of the scaffolding will not be started until the previous level has been fully
assembled with all its stabilizing elements.
 The previously completed level will offer the necessary safety guarantee in order for
safety belts to be attached to it.
 The bars, tubular modules and boards will be hoisted using ropes tied with sailor’s knots.
 Work platforms will be consolidated immediately upon completion of the scaffold level
using clamps and diagonal braces to prevent swaying.
 Clamps will all be fully secured. Completed levels will be inspected before beginning the
next level to ensure that there are no loose or missing bolts and screws.
 Scaffolding pipes will be connected using bolt or anchor ties or using the clamps and pins
provided.
 Work platforms or levels minimum width of 0.60 will have a meters and a load resistance
of 160 kg at the mid point between supports. The safety railings of work platforms will
have a minimum height of 90 cm, including an intermediate railing and foot boards of 15
cm. Platforms, levels, walkways, etc, formed by boards will be secured using fasteners,
wire loops, nailed transoms in order to form a complete and united whole. The base of the
scaffolding will be protected from impacts and shifting using wedges, blocking systems
 and/or stabilisers. Once the scaffolding has been assembled, no part of its structure will
be removed (pipes, boards, braces, etc) until the scaffolding is to be completely
disassembled. In the case the work requires the structure to be maintained for several
days using parts of the scaffolding to create other scaffolding, access will be prohibited
and clearly sign posted.

32. Disconnection And Work Orders.

All work to be performed on High Voltage installations which imply proximity or work on the
live elements will require a prior request for the authorisation and execution of a Disconnection
Order for said installation as established in the corresponding Disconnection Management
procedures.

The opening of telecontrolled cutting elements does not free from the obligation to use local
disconnections, immobilization and local signs.

The operations on an installation which is in service will only be carried out by a contractor
which has been expressly authorized to perform these operations. This will be established in the
corresponding service contract which will include the certification of the appropriate training and
qualifications required.

For work or services which require disconnection, the Disconnection Agent will perform the
necessary actions and will create, delimit and sign post a protected work area. The Agent will
provide this work area to the Project Supervisor of the Contractor with a completed and signed
document certifying the hand-over and return of the disconnected installation for the work
required.

The Project Supervisor will be responsible for the creation and delimitation of the work area, to
be supervised by the person designated by the Site Manager before beginning the work.

The operator will follow the recommendations indicated below when requesting the
disconnection of equipment in order to execute a connection: -

 The DISCONNECTION of a system or element of the same is to guarantee your

SAFETY by shutting down a system or element during the execution of the work. -
 All WORK ORDERS will indicate if a DISCONNECTION is required.
 If a DISCONNECTION is necessary, work will not be initiated until the corresponding
DISCONNECTION ORDER has been duly carried out.
 Photocopies without authorisation from CONTROL or verbal communications are not
considered a valid DISCONNECTION ORDER.
 The DISCONNECTION ORDER is not sufficient to prevent ACCIDENTS. Verify that
the DISCONNECTION of the system has been carried out correctly.
  When the work is complete, a CANCELLATION OF DISCONNECTION will be
submitted, returning the DISCONNECTION ORDER to CONTROL.
 Request a DISCONNECTION ORDER if you believe it is necessary.
 VERIFICATIONS AND CHECKS BEFORE WORK BEGINS -
 Installations will be checked to ensure there are no anomalies which may cause a
workplace accident.
 In the case an anomaly is detected which cannot be corrected, an Anomaly Notification
Sheet will be completed for the installation, appropriate safety measures will be taken and
warning signs posted.
 The position(s) of subject to the work will be clearly indicated, not allowing any possible
confusion or doubt.
 A power meter will be used to ensure the absence of tension in the position where the
work is being carried out. This meter will be appropriate for the level of tension of the
position.
 In the case it is necessary to open breakers without gear, there will a manoeuvring pole
suitable for the voltage threshold.
 A sufficient number of grounds will be installed to isolate the work area from all possible
sources of tension. These grounds will be appropriate for the level of tension of the
position.
 Elements will be on hand (red tape, signs, etc) to indicate and delimit work areas.
 All personnel will be equipped with the necessary Personal Protective Equipment.
 All tools and equipment used will be in perfect working condition.
 When using scaffolding or ladders, these will be checked to ensure they are in perfect
condition.
 Communication devices will be in perfect working order.
 A protected area will procedure register.be created in accordance with the disconnection
 A work area will be created in accordance with the disconnection procedure -beregister.
The appropriate safety distances will be maintained from the nearest live elements. This
safety area will allow work to be performed without the used of insulating screens or
other safety measures. –

33. Work Installations.

When moving cranes, work platforms, etc, the appropriate safety distances will be maintained at
all times. These distances area 3 meters for installations up to 66 kV and 5 meters for higher
tension. For tensions higher than 380 KV, a safety distance of 7 meters will be maintained. In the
case the crane boom can accidentally encroach in this safety distance, it will be necessary to
block the boom in order to guarantee unintentional contact with live installations.
Notwithstanding the above, minimum safety distances will be maintained at all times. Tasks will
be performed under the supervision of a qualified supervisor who will ensure that established
safety measures and procedures are followed, including the delimitation of work areas and the
installation of insulated safety screens if necessary. If situations of possible risk persist, a
Disconnection request will be presented or the work will be performed following the Work with
Live Installations safety requirements. Under adverse weather conditions (strong winds, etc.) the
safety distances indicated above will be increased, non-conductive auxiliary equipment will be
used to direct loads, and the work area will be shielded from live elements or work may be
discontinued altogether. When performing work of this type, a corresponding ground connection
will be installed for hoisting equipment. The work area will be expanded, appropriately delimited
and sign posted, to include activity radius of the crane boom both horizontally and vertically, if
this is not enclosed within the established work area itself.

34. Order Principles and Cleanliness:

The work will be carried out paying special attention and care to the organization of
transportation, storage and stockpiling of required materials, tools, equipment and machinery.
Transit routes of the site will be free of obstacles and allow personnel and vehicles to access any
part of the installation.The areas to be used for storing and stockpiling materials will authorised
before the execution of the work.

During the performance of the works or the termination of the same, extra materials and waste
products generated will be stored in appropriate locations to avoid the risk of accidents, robbery
and/or any other type of violent action.

The area will be maintained in its habitual condition, both functionally and in terms of
cleanliness, without harm to other proprietors or third parties.

It is obligatory to maintain constant supervision of the order and cleanliness of the work site.

35. Manual Handling Of Loads

Organizational measures will be taken, or the appropriate equipment will be used, in order to
reduce the need for manual handling of loads as much as possible. The maximum load weight
carried by an operator, 40 kg, will not be exceeded (recommended load weights are 30 Kg for
men, 15 Kg for women). Personnel will receive the appropriate training and information about
the correct handling of loads and the risks involved especially when these actions are not
performed correctly from a technical point of view. Personnel will remove all metal jewellery,
especially all types of rings. Packages and their shape will take into consideration ease of
handling, especially with regards to weight and the elimination of aggressive or cutting edges.
Packages will be free of grease or slippery substances. The load and the manner in which it is
carried will not impede visibility. Operators will never walk backwards while carrying loads.
Transit routes will be planned carefully, taking into consideration: lighting, obstacles, ramps,
slopes, the condition and stability of the terrain, free areas, the stability of possible supports, etc.
Prior to handling objects, certain factors will be considered, such as form (volume, shifting
contents, difficulty in gripping) and physical properties (fragility, rigidity, etc).

PART:B
Methodology For 132kv & 66kv Transmission Lines

Introduction:
The lines that carry radio waves from the radio transmitter to the antenna are known as
transmission lines, their purpose is to convey radio-frequency energy with minimum heating
and radiation loss. Heating losses are reduced by conductors of adequate size. Transmission
lines are sets of wires, called conductors, that carry electric power from generating plants to
the substations that deliver power to customers. At numerous substations on the transmission
system, transformers step down the power to a lower voltage and deliver it to distribution
lines. Types of transmission line include parallel line (ladder line, twisted pair), coaxial
cable, and planar transmission lines such as stripline and microstrip. The higher the
frequency of electromagnetic waves moving through a given cable or medium, the shorter the
wavelength of the waves.
 These transmission lines will use a combination of lattice towers and support poles. The
materials for construction needed for each tower are brought to site and distributed along the
right-of-way where the towers will be built. Smaller poles are placed between the towers to
support the transmission cables. Transmission line voltages vary from 44,000 to over 765,000
volts. The higher the voltage, the more electricity the line can carry. Where the vertical distance
above ground of conductors of 7,500 volts or less is in excess of 35 feet, this horizontal clearance
from buildings shall be permitted to be less than 6 feet, but shall be not less than 4 feet.
Technical aspects of power lines installation require adherence to national and
international standards for construction quality and labour safety. Our company is certified for
compliance with ISO management standards (Quality Management System, Environmental
Management System, Occupational Health and Safety Management System). In power lines
installation, it is important to effectively plan the working process, engage qualified staff, and
ensure availability of equipment and special-purpose machinery. Our experienced technicians
and administrative employees monitor and control progress of works at all stages of power line
construction.
A transmission tower (also known as a power transmission tower, power tower, or electricity
pylon) is a tall structure (usually a steel lattice tower) used to support an overhead power line. In
electrical grids, they are used to carry high voltage transmission lines that transport bulk electric
power from generating stations to electrical substations; utility poles are used to support lower-
voltage sub-transmission and distribution lines that transport power from substations to electric
customers.
Transmission towers have to carry the heavy transmission conductors at a sufficient safe height
from the ground. In addition to that, all towers have to sustain all kinds of natural calamities. So
transmission tower design is an important engineering job where civil, mechanical, and electrical
engineering concepts are equally applicable.
Transmission Tower Parts
A power transmission tower is a key part of a power transmission system. A power transmission
tower consists of the following parts:
1. The peak of the transmission tower
2. The cross arm of the transmission tower
3. The boom of transmission tower
4. Cage of transmission tower
5. Transmission Tower Body
6. Leg of transmission tower
7. Stub/Anchor Bolt and Baseplate assembly of the transmission tower.
These parts have been described below. Note that the construction of these towers is not a simple
task, and there is a tower erection methodology behind building these high voltage transmission
towers.
 1. Peak of Transmission Tower
The portion above the top cross arm is called peak of transmission tower. Generally earth shield
wire connected to the tip of this peak.
Cross Arm of Transmission Tower
Cross arms of transmission tower hold the transmission conductor. The dimension of cross arm
depends on the level of transmission voltage, configuration and minimum forming angle for
stress distribution.
Cage of Transmission Tower
The portion between tower body and peak is known as cage of transmission tower. This portion
of the tower holds the cross arms.
Transmission Tower Body

The portion from the bottom cross arms up to the ground level is called the transmission tower
body. This portion of the tower plays a vital role in maintaining the required ground clearance of
the bottom conductor of the transmission line.

2. Transmission Tower Design

During design of transmission tower the following points to be considered in mind,

 The minimum ground clearance of the lowest conductor point above the ground level.
 The length of the insulator string.
 The minimum clearance to be maintained between conductors and between conductor
and tower.
 The location of a ground wire with respect to outermost conductors.
 The midspan clearance required from considerations of the dynamic behavior of the
conductor and lightning protection of the power line.
To determine the actual transmission tower height by considering the above points, we have
divided the total height of the tower into four parts:
1. Minimum permissible ground clearance (H1)
2. Maximum sag of the overhead conductor (H2)
3. Vertical spacing between the top and bottom conductors (H3)
4. Vertical clearance between the ground wire and top conductor (H4)
The higher the voltage of the transmission line, the higher the ground clearance and verticle
spacing tends to be. i.e. high voltage towers will have a higher permissible ground clearance and
larger verticle spacing between the top and bottom conductors.
 Types of Electrical Transmission Towers
According to different considerations, there are different types of transmission towers.
The transmission line goes as per available corridors. Due to the unavailability of the shortest
distance straight corridor transmission line has to deviate from its straightway when obstruction
comes. In the total length of a long transmission line, there may be several deviation points.
According to the angle of deviation, there are four types of transmission tower–
1. A – type tower – angle of deviation 0o to 2o.
2. B – type tower – angle of deviation 2o to 15o.
3. C – type tower – angle of deviation 15o to 30o.
 4. D – type tower – angle of deviation 30o to 60o.
As per the force applied by the conductor on the cross arms, the transmission towers can be
categorized in another way-
1. Tangent suspension tower and it is generally A – type tower.
2. Angle tower or tension tower or sometime it is called section tower. All B, C and D types
of transmission towers come under this category.

Apart from the above-customized type of tower, the tower is designed to meet special usages
listed below:
These are called special type tower
1. River crossing tower
2. Railway/ Highway crossing tower
3. Transposition tower
Based on numbers of circuits carried by a transmission tower, it can be classisfied as-
1. Single circuit tower
2. Double circuit tower
3. Multi circuit tower.

 Stages of Project implementation:

Project implementation starts with design and engineering of overhead lines, which includes:
1. Preparation of technical design assignment for the designed object.
2. Feasibility study and selection of the optimal transmission line route.
3. Engineering surveys and collection of necessary input data
4. Development of design documentation for the construction of the overhead power line.
5. Coordination of engineering documentation with owners of power networks and other
parties concerned.
6. Expert examination of design and estimate documentation for construction.
Before the start of overhead transmission line construction, our company carries out preparatory
works, which are discussed as below.

 Transporting materials to the tower sites and site preparation

The materials for construction needed for each tower are brought to site and distributed along the
right-of-way where the towers will be built. Smaller poles are placed between the towers to
support the transmission cables.
After completing site surveys, flagging and placing a call to BC One Call, the crews carefully
remove the topsoil, and any necessary tree removal and brushing. Access roads are built so
construction vehicles and equipment can travel to the site.
 Building the foundations and anchors
Different types of foundations may be used to support the towers, depending on the soil type,
depth of bedrock, and structure type. Excavation may be done with a mechanical excavator,
hydrovac, auger, or hand digging.
 Assembling the towers
Towers are generally built from the ground up. Line workers assemble the towers on the ground
near the tower location ,much like a giant, complicated 3D puzzle. This includes the use of heavy
machinery. In areas that have soft ground composition, access mats (sometimes called rig mats)
may be used to provide passage over the sensitive ground. Access mats provide structural
support for equipment by dispersing weight and providing a solid base. 

There are four main methods of the erection of steel transmission towers which are described
below:
1. Build-up method or Piecemeal method.
2. Section method.
3. Ground assembly method.
4. Helicopter method.

1. Build Up Method of Transmission Tower Erection

This method is most commonly used in Pakistan for the erection of 6.6 kV, 132 kV, 220 kV, and
400 kV transmission line towers due to the following advantages :

1. Tower materials can be supplied to the site in a knocked down conditions which
facilitates easier and cheaper transportation.
2. It does not require any heavy machinery such as cranes etc.
3. Tower erection activity can be done in any kind of terrain and mostly throughout the
year.
4. Availability of workmen at cheap rates.
This method consists of erecting the towers, member by member. The tower members are kept
on the ground serially according to the erection sequence to avoid search or time loss. The
erection progresses from the bottom upwards.

The four main corner leg members of the first section of the tower are first erected and guard off.
Sometimes more than one contiguous leg section of each corner leg is bolted together at the
ground and erected.

The cross braces of the first section which are already assembled on the ground are raised one by
one as a unit and bolted to the already erected corner leg angles. First section of the lower thus
built and horizontal struts (belt members) if any, are bolted in position. For assembling the
second section of the tower, two gin poles are placed one each on the top of diagonally opposite
corner legs.

These two poles are used, for raising parts of the second section. The leg members and braces of
this section are then hoisted and assembled. The gin poles are then shifted to the corner leg
members on the top of the second section to raise the parts of the third section of the lower in
position for assembly. Gin poles are thus moved up as the tower grows.

This process is continued until the complete tower is erected. Cross-arm members are assembled
on the ground and raised up and fixed to the main body of the tower. For heavier towers, a small
boom is rigged on one of the tower legs for hoisting purposes. The members/sections are hoisted
either manually or by winch machines operated from the ground.

For smaller base towers/vertical configuration towers one gin pole is used instead of two gin
poles. In order to maintain speed and efficiency, a small assembly party goes ahead of the main
erection gang and its purpose is to sort out the tower members, keeping the member’s incorrect
position on the ground and assembling the panels on the ground which can be erected as a
complete unit.

2. Section Method of Transmission Tower Erection

In the section method, major sections of the tower are assembled on the ground and the same
are erected as units. Either a mobile crane or a gin pole is used. The gin pole used is
approximately 10 m long and is held in place by means of guys by the side of the tower to be
erected.
The two opposite sides of the tower section of the tower are assembled on the ground. Each
assembled side is then lifted clear of the ground with the gin or derrick and is lowered into
position on bolts to stubs or anchor bolts.
One side is h held in place with props while the other side is being erected. The two opposite
sides are then laced together with cross members and diagonals; and the assembled section is
lined up, made square to the line. After completing the first section, the gin pole is set on the
top of the first section. The gin rests on a strut of the tower immediately below the leg joint.
The gin pole then has to be properly guyed into position.
 The first face of the second section is raised. To raise the second face of this section it is
necessary to slide the foot of the gin on the strut of the opposite face of the tower. After the
two opposite faces are raised, the lacing on the other two sides is bolted up. The last lift
raises the top of the towers.
After the tower, the top is placed and all side lacing has been bolted up all the guyed are
thrown off except one which is used to lower the gin pole. Sometimes whole one face of the
tower is assembled on the ground, hoisted, and supported in position. The opposite face is
similarly assembled and hoisted and then the bracing angles connecting these two faces are
fitted.
3. Ground Assembly Method of Tower Erection
This method consists of assembling the tower on the ground and erecting it as a complete
unit. The complete tower is assembled in a horizontal position on even ground. The tower is
assembled along the direction of the line to allow the cross arms to be fitted. One slopping
ground, however, elaborate packing of the low side is essential before assembly commences.
After the assembly is complete the tower is picked up from the ground with the help of a
crane and carried to its location, and set on its foundation. For this method of erection, a level
piece of ground close to footing is chosen from the tower assembly.
This method is not useful when the towers are large and heavy and the foundations are
located in arable land where building and erecting complete towers would cause damage to
large areas or in hilly terrain where the assembly of the complete tower on the sloping ground
may not be possible and it may be difficult to get the crane into position to raise the complete
tower.
In India, this method is not generally adopted because of the prohibitive cost of mobile crane,
and the non-availability of good approach roads to tower locations.
4. Helicopter Method of Transmission Tower Erection
In the helicopter method, the transmission tower is erected in section. For example, the
bottom section is first lifted on to the stubs and then the upper section is lifted and bolted to
the first section and the process is repeated till the complete tower is erected.
Sometimes a completely assembled tower is raised with the help of a helicopter. Helicopters
are also used for lifting completely assembled towers with guys from the marshaling yards
where these are fabricated and then transported one by one to line locations. A helicopter
hovers over the line location while the tower is securely guyed.
The ground crewmen connect and tighten the tower guys. As soon as the guy wires are
adequately tensioned the helicopter disengages and files to the marshaling yard. This method
is adopted where the approach is very difficult or to speed up the construction of the
transmission line.
 Tightening of Nuts and Punching of Threads and Tack Welding of Nuts of
Transmission Towers
All nuts shall be tightened properly using correct sized spanners. Before tightening it is
ensured that filter washers and plates are placed in relevant gaps between members, a bolt of
proper size and length are inserted and one spring washer is inserted under each nut.
In the case of step bolts, the spring washer shall be placed under the outer nut. The tightening
shall be carried on progressively from the top downwards, care being taken that all bolts at
every level are tightened simultaneously. It may be better to employ four persons, each
covering one leg and the face to his right.
 The threads of bolts shall be projected outside the nuts by one to two threads and shall be
punched at three positions on the top inner periphery of the nut and bolt to ensure that the
nuts are not loosened in course of time. If during tightening a nut is found to be slipping or
running over the bolt threads, the bolt together with the nut shall be changed outright.
 Painting of Joints of Transmission Tower
For galvanized towers is coastal or highly polluted areas, the joints shall be painted with zinc
paint on all contact surfaces during the course of erection.
 Checking the Verticality of Erected Transmission Towers
The finally erected tower shall be truly vertical after erection and no straining is permitted to
bring it in alignment. The tolerance limit for vertical shall be one in 360 of the tower height.

 Raising the towers and poles

Tower sections are either assembled all in one piece, or in multiple pieces that are connected
after they are raised. Telescopic cranes or helicopters are used to raise the tower sections from
the ground, and bolt them together to complete assembly.
Poles are used to support cables between transmission towers and to maintain the tension of the
cable. Framing and hardwire installation will be completed before the poles are installed, then
lifted and set into place.
 Unreeling and installing the conductors
The conductors, which are the lines that transport the power, are unreeled and strung from tower
to tower using a cable drum. On one end, there is a reel and tensioner, and at the other there is a
puller and take-up reel. The conductors are pulled with the puller machine between each of the
towers and poles. The puller and tensioner work in conjunction to ensure the conductor
maintains a safe ground clearance so it is not damaged. Multiple wire pulling stations are located
along the span of the transmission line. Once the conductor is pulled through the entire length of
the line, the tensioner is used to achieve the proper sag. Having the right sag in the line keeps the
line from sagging too low as the lines expand and contract with temperature changes.
Wire installation using the pulling method has the following main stages:
 preparatory works;
 uncoiling and pulling the lead line;
 pulling a wire using the lead line;
 wire tensioning, alignment and fastening;
 wire mounting, installation of line spacers.

 Site restoration
After the transmission line is strung and grounded, cleanup and restoration of the site begins.
This includes:
 Removing all waste and debris
 Levelling the ground
 Dismantling any temporary access points
 Repairing infrastructure
 Seeding and planting as necessary 
Throughout the project, site supervisors ensure all environmental, health and safety, and quality
standards are being met.
 Safety
The safety of employees, customers, and the general public is extremely important to the
company. Our employees work in difficult areas and cover thousands of kilometers every year.
Keeping people safe is the most important task. In addition to all other tasks, we persistently
maintain a safe work environment and care about preserving the environment. Safety is a matter
of compliance with national and international norms and laws.
 Quality
We pay the same attention to the quality of our services. In this regard, all employees and
partners work to ensure high-quality standards. Quality management system and project planning
allow us to consistently provide a high level of performance according to customer
specifications, drawings, and documentation for all projects, which we carry out. This is
achieved through continuous improvement of quality and safety, which ensures the effective
planning, operation, and execution of all processes.