Aux Electrical PDF

FOR INTERNAL CIRCULATION ONLY
users manual
of
Construction
(part two)
Sub-Stations
Volume-5
Auxiliary Packages
(Electrical)
Construction Management
Power Grid Corporation of India Limited

(A Government of India Enterprise)
DOCUMENT CODE NO. : CM/AP/AUX. PKG. (ELECT.)/96
DEC. 1996
CHAIRMAN
&
MANAGING DIRECTORS MESSAGE
It
gives
me
immense
pleasure
to
learn
that
Construction
Management Deptt. has come out with further 3 volumes of users

manual of construction of transmission line (Stringing) & sub-station
(Mechanical and Electrical auxiliary packages)
For quite sometime a need was also being felt in the organization to
develop and prepare standard procedures, norms and guidelines for
execution of various construction activities as the different regions
were following different practices. It is with this background the
construction management department was conceived at Corporate
Centre and entrusted with the task of developing and providing such
users manuals of construction and to bring in uniformity. These
manuals shall service as a useful reference to our field engineers
and site managers to accomplish a task in given time, cost & quality.
I would like to congratulate Construction Management team for its
sincere efforts in preparation of these manuals wherein the main
focus has been to bring together all the theoretical and practical
knowledge acquired during the years in the domain of construction of
overhead transmission lines and s/stn. More such users manuals
covering the other related fields in the lines/sub-station construction
should be prepared for the benefit of the ultimate users at our remote
sites as well as for the younger generation inducted in the
POWERGRID.
(R.P. SINGH)
CONTENTS
CHAPTER-1
BATTERY & BATTERY CHARGER
PAGE NO.
1.0
NEED FOR PROVIDING BATTERY

SUPPORTED DC SYSTEM
1.1
FUNCTIONS
1.2
CHOICE OF BATTERY TYPES
1.3
SPECIFYING A BATTERY
1.6
1.4
CHARGER/CHARGING EQUIPMENT
BATTERY
6
1.5
CHARGING
FLOAT
9
1.6
VARIFICATION IN THE CHOICE OF FLOAT VOLTAGE 11

1.7
BOOST CHARGING
13
1.8
RECEIPT OF BATTERIES
20
1.9
STORAGE OF BATTERIES
21
1.10
RECEIPT & STORAGE OF BATTERIES CHARGERS
22
1.11
ELECTROLYTE PREPARATION
23
1.12
ERECTION AND COMMISIONING
25
1.13
FIRST CHARGE
26
1.14
CAPACITY TEST
31
1.15
RECHARGE
32
1.16
FIELD QUALITY PLAN
33
GUIDELINES
SPECIAL POINTS WITH REGARD TO INSTALLATION
OF LARGE CAPACITY STATIONARY CELLS
35
1.18
36
UN-PACKING ACCESSORIES
PREPARATIONS BEFORE ERECTION &

COMMISSIONING
36
1.20
PRECAUTIONS DURING BATTERY INSTALLATION
37
1.21
RATED AMPERE-HOUR (AH) CAPACITY
40
PRECAUTIONS DURING INITIAL FILLING OF

ELECTROLYTE
44
1.23
CAUTION
45
1.24
IMPORTANT INSTRUCTIONS
46
1.25
BATTERY CAPACITY
47
1.26
CALCULATION OF BATTERY CAPACITY
48
1.27
FACTORS AFFECTING BATTERY LIFE
51
1.28
BEING CONVERSANT WITH THE ACCESSORIES
52
1.29
REPORTING DISCREPANCIES
53
CHECK FORMAT
54
CHAPTER-2
STATION LIGHTING
2.0
SCOPE OF WORK IN A SUBSTATION LIGHTING
CONTRACT
58
2.1
CATEGORIES OF SUBSTATION LIGHTING
58
2.2
MINIMUM LUX LEVELS
59
2.3
DISTRIBUTION SCHEME OF LIGHTING
61
GUIDELINES
2.4
DC LIGHTING
62
2.5
RECEIPT OF MATERIALS AT SITE
62
2.6
INSPECTION OF MATERIAL
63
2.7
STORAGE
64
2.8
ERECTION
65
2.9
FIELD QUALITY PLAN
74
2.10
CONSTRUCTIONAL FEATURES
76
2.11
PAINTING FOR SHOP MADE ITEMS
83
2.12
TEST AND TEST REPORTS
84
2.13
IMPORTANT INSTRUCTIONS
84
CHECK FORMAT
CHAPTER-3
AUXILIARY POWER SUPPLY
3.0
33KV-11KV/415 V SUBSTATION
106
3.1
EQUIPMENTS IN 11/33KV/415V SUBSTATION
106
3.2
CLASSIFICATION OF ACTIVITIES
107
3.3
RECEIPT OF MATERIALS
107
3.4
INSPECTION OF MATERIALS
108
3.5
STORAGE
108
3.6
SUBSTATION LAYOUT
109
3.7
SUPPLY AND ERECTION OF EQUIPMENTS
109
3.8
COMMISSIONING TESTS
109
3.9
PRECOMMISSIONING TEST FORMATS FOR

LT SUBSTATION
110
3.10
PRECOMMISSIONING TEST RESULTS
113
3.11
INSPECTRION BY CEA TO ENERGISE THE EQUIPMENT
117
3.12
RELEASE OF SUPPLY BY THE STATE ELECTRICITY

BOARD
117
3.13
3.14
TECHNICAL SPECIFICATION
PERFORMANCE GUARANTEE
118
126
3.15
RECEIPT AND JOINT INSPECTION
127
3.16
ERECTION SUPERVISION
127
3.17
COMMISSIONING
128
3.18
PROGRESS REPORTS AND REVIEW MEETINGS
129
3.19
PROGRESS PAYMENTS
129
3.20
GENERAL
130
ANNEXURE-I
133
ANNEXURE-II
135
CHECK FORMAT
138
________________________________________________________________
CHAPTER
ONE
________________________________________________________________
SUBSTATION BATTERY & BATTERY CHARGER
Back to contents page
1.0
Need for providing battery supported dc system

Besides the A.C. Supply which is not perfectly reliable another

reliable source of auxiliary power is essential at Sub-stations for
specific purposes. Battery is required for specific purposes as
listed below. This source is available for limited periods. Suffice it to
say that a storage battery capable of being charged at convenient
rate, such that it can store enough quantity of readily available
energy which can be delivered at any time at the required rate and
place without delay is eminently suitable for these applications. The
use of storage battery for such applications is universal and
undisputed.
1.1
Functions
Storage batteries are provided for the following functions.
i)
Supply to trip coils and closing coils of switchgears or
ii)
Indication: Indicating lamps, facia
iii)
Semaphores
Alarms
For energising the holding and operating coils in control

and interlock schemes, and in protection schemes.
iv)
For power supply to communication including PLCC

equipments and other supervisory equipment.
v)
For providing power supply to EDP System.
vi)
For emergency DC lighting.
vii)
Electric impulses for impulse clocks.

Choice of Battery types
1.2

i)
The most commonly used type of battery in electrical

installation for performing the functions listed above is the
storage battery consisting of lead-acid cells. Other types of
batteries comprising Nickel-Cadmium or Nickel-iron cells
also serve the purpose. Nickel-Cadmium batteries have long
life and require less maintenance. These have high
reliability, large load capacity, less weight and wide
temperature range adoptability. These batteries with much
smaller AH ratings than lead-acid batteries, can supply high
discharge rate loads for short durations. These can be used
for unattended Substations. The Nickel-Cadmium battery
has a life atleast three times that of a lead-acid one.
Although some indigenous manufacturers have initiated

manufacture of Nickel-Cadmium batteries in the country,
lead-acid cells are being manufactured in India mostly
and therefore batteries consisting of such cells are being
used in India most commonly for the above applications.
ii)
Lead acid cells are of three designs based on the

construction of their positive and negative plates.
These plates are of the following types

a)
Plante positive plate with pasted negative plate,
b)
Tubular positive plate with pasted negative plate and
c)
Pasted positive plate with pasted negative plate.

Duty cycle (i.e. the value of discharge current, duration of
discharge and the
voltages),
maximum
frequency of
and
use,
minimum acceptable
depth
of discharge,
temperature of operation, quality of maintenance have a

great bearing on the life
expectancy
of battery and
therefore on the choice of the type of battery.

Cells with plante positive plate are suited for applications
requiring supply of large currents
for short durations as
required in unattended substations whereas the cells with

tubular positive plates are suitable for the supply of smaller
currents for medium to long durations. Economy and life
expectancy become guiding factors in their choice for
application in sub-stations. The relative representative
figures for the three designs are indicated in Table 1.
Table-1
---------------------------------------------------------------------------------------------------------Type
Plante
Tubular
Flat (Pasted)
---------------------------------------------------------------------------------------------------------Capacity (Ah)
400
400
400
Initial Cost (Percentage)
100
75-80
70
Life (Percent)
100
60-70
50-60
----------------------------------------------------------------------------------------------------------
The best value for money can be worked out by capitalising the interest on the
capital cost. However, when optimum maintenance and correct operation cannot
always be ensured in practice, the full battery life may actually not be realized
and it may turn out to be more economical to make a lower initial investment.
From this stand point, tubular positive plate batteries may offer a good
compromise. Pasted plate batteries are usually not used in Sub-stations.
Use of glass containers is preferable over the other types as these facilitate
checking up of sedimentation, electrolyte level, condition of plates separators
etc.
1.3
Specifying a battery
i)
The
details
of
constructional
features,
expected
performance and tests for cells of the three types dealt

should confirm to the late revisions of the following Indian
Standard Specifications :
a)
Plante Cells
IS: 1652-1984
b)
Tubular Cells
IS: 1651-1979
c)
Flate pasted Cells
IS: 6304-1980
d)
Electro-Technical
IS 1885 (Part
Vocabulary
ii)
VIII)- 1965
The following parameters have to be selected
to meet the specific requirements in each application

keeping voltage
variation acceptable for the loads, load
cycle and the minimum voltage during the discharge cycle

in view :
-
Voltage and number of cells in the battery and
Rated Ampere-hour capacity.
a)
The voltage of a lead-acid cell being 2 volts per cell,

the number of cells in the battery would be half of the
rated D.C. Voltage adopted. In some cases, however,
the number of cells has to be varied to facilitate
maintenance of D.C. voltage between close limits.
b)
It
is
rare
that
communication
and
substation
requirements are combined and met from a common

battery. Usually separate battery is installed for
communication equipment as it is helpful in obviating
the possibility of any operational difficulty during
serious emergencies where
battery utilisation can
approach design limits. The choice of communication

battery voltage has to be made according to voltage
rating of the communication equipment already
existing or that to be installed. In the absence of any
precedent 48 volts is normally found to be optimum
for most installations.
1.4
Battery Charger
i)
A dc source having the adequate voltage and current

capacity is required for battery charging. Formerly a dc
generator meeting the above requirements, driven by an
induction motor was used. However, as the above involved
the use of rotating machinery it got replaced by static
devices like selenium Rectifiers and Silicon Rectifiers. With
the advancements in the manufacture of silicon rectifiers
indigenously, now Silicon Rectifiers are used mostly for
battery charging.
ii)
In smaller substations (11-33 kV Capacity) float charger

voltage is adjusted manually by means of manually
operated step less variacs to keep the output voltage
constant within the required limits. In larger substations,
having large sized batteries and load consisting of more
sophisticated equipment, automatic voltage stabilizers are
incorporated in the battery charger to keep the output
voltage value stable within 1% of the rated dc supply

voltage, throughout the dc load variation from 5% to 100%
and for ac supply voltage fluctuation of 10%, frequency
variation of 5% and combined voltage and frequency
fluctuation of 10%.
iii)
Battery chargers with automatic voltage stabilizers are

based
on electronic circuits for
load
current detection,
error detection, amplification of error and correction, which

is achieved either through motorised variacs control or
thyristor control. For such chargers to give reliable service,
great
care
in
selection
and
use
of
proper
quality
components is imperative. Magnetic amplifier (transductor)

type control is simpler and more rugged. However it is more
suited for applications where high speed response is not
very
important.
Motorised
variacs
require
regular
maintenance and provision of inching for correction of small

error to overcome their inherent sluggishness.
iv)
The output of static rectifiers contains a large proportion of

harmonics. In single phase bridge rectifiers, the ripple
content can be as high as 48% of the fundamental. Such
high ripple may not be desirable for many of the
sophisticated equipments. Therefore, suitable filters are
used with single phase rectifiers to reduce the ripple content
to about 5% which is satisfactory for most of the
applications. A rectifier comprising three-phase bridge circuit

has inherently low ripple content of the order of 5% only and
therefore does not require any harmonic filters. The ripple
content of the voltage wave form should be restricted to 2%
with fully charged batteries for communication system.
v)
Thyristor control of voltage is also associated with high

ripple content and requires use of carefully designed filters
of ample size to reduce the ripple content to acceptable
level.
1.5
Float Charging
There are a number of methods of battery charging which are
designed to suit a particular application. However, for substations,
the batteries almost universally are "Float" operated. This term
applies to the method of operation in which battery remains
connected to the load and the charger continuously. Voltage of
charger is substantially constant and just higher than open circuit
voltage of the battery. To keep the battery in a fully charged
condition, the charger sends through the battery charging current
of a few mill amperes at a voltage which is sufficient to compensate
for local action and leakage losses. The magnitudes of the
charging current and the voltage should be recommended by the
battery suppliers. The charger also supplies the entire D.C. Load
under normal condition.
The following alarms, indicators and metering are commonly

associated with the chargers:
vii)
Alarm/Indicators
a)
Main incoming AC supply on
b)
DC supply on
c)
Float charger failure
d)
Boost charger failure
e)
AC failure
f)
DC over load
g)
Float output DC fuse failure/MOCB trip
h)
Boost output DC fuse failure/MOCB trip
i)
Earth leakage
j)
Controller card defective.
viii)
Metering
a)
AC incoming voltmeter
b)
DC output voltmeter for float charger
c)
DC output voltmeter for boost charger and battery with

selected switch
d)
DC ammeter for float output
e)
DC ammeter for boost output
f)
DC ammeter (centre-zero) to measure trickle charging

current to battery as well as discharging current from
battery.
Many-a-time the interconnecting cables between battery,
charger and DC board are fairly large in size and can

not be conveniently connected to the charger. Therefore
a battery panel or a marshalling panel which has incomer
from battery, charger and DC board has to be provided
for accommodating the connections.
The charging arrangement ensures that on failure of AC
supply and thereby disappearance of the charger output,
the battery starts feeding the vital loads of the control
and protection systems. If the failure of AC supply
persists for a long duration, or the battery goes through a
major design discharge cycle resulting in depletion of the
charge of the battery then it becomes necessary to resort
to boost charging of the battery as soon as the AC supply
gets restored.
1.6 Variations in the choice of 'float' voltage
The 'Float' voltage being higher than the nominal voltage per cell,
the D.C. bus voltage is also higher than the rated voltage. For
example a float voltage of 2.2 volts per cell would raise the DC bus
voltage to 121 volts in a 110 volt system with a 55 cell battery.
(Fig. 1.1) Although the bus voltage is about 10% higher than the
rated voltage, it is acceptable for most applications. However, if on
account of special considerations variation of this order is not
permissible for a particular application one of the following
charging procedures may be adopted.

1.6.1
Selecting a lower float voltage

The minimum float voltage should normally be 2.2 volts per cell. If
a lower floating voltage is adopted, it will call for application of
equalising charges more frequently. Table-2 gives an idea of the
intervals at which equalising charges have to be applied
corresponding to the different floating voltages.
TABLE - 2
-----------------------------------------------------------------------------------------------------------Float voltage I per cell

Interval between equalizing charge
-----------------------------------------------------------------------------------------------------------2.2 Volts
12 Months
2.15 Volts
3 Months
2.10 Volts
2 Months
2.08 Volts
1 Months
----------------------------------------------------------------------------------------------------------Equalizing charge is given to battery generally at 3 month intervals to bring

up/equalize the specific gravity of the cells. The charging current for this
operation is maintained at about 40% of the rated 10-hour capacity till the battery
is fully charged.
1.6.2
Selecting smaller number of cells in battery

By selecting a smaller number of cells in battery, the DC supply
voltage can be effectively controlled and a higher float voltage per
cell upto 2.5 volts can be attained. In this case, the need for a
freshening charge gets completely obviated which is a great
advantage. However, this introduces the problem of low voltage on

failure of AC supply when the battery approaches nearly discharge
state. Under such condition the voltage per cell may go down to
about
1.85 volts and the required voltage at
terminals of the
farthest may not be available.
1.7 Boost charging
Boost charging of battery is required to restore the specific gravity

of the electrolyte in the cells to their fully charged value. Boost
charging is done by charging the battery at a high rate till the
specific gravity of electrolyte in the cells is restored to the fully
charged value of 1.200 + 0.005 at 27C. This rate should be as
high as is consistent with the pace of chemical reaction taking
place in the battery. If charging current higher than that consistent
with the chemical reaction is sent into the battery, the whole of
it will not be utilised for charging the cells and it will result in
break-down of water in the electrolyte and liberation of hydrogen
and oxygen gases. This liberation of gases is called gassing.
Violent gassing can result in shedding of active material from the
plates and damage to the cells. Too high a charging current can
also produce excessive heating which also can damage the cells.
The temperature of Electrolyte should not normally be allowed to
exceed 38C but in no case more than 50C during charging. If
temperature tends to increase, the charging current may be

reduced and period of charge may be increased proportionately.
1.7.1
Boost charging scheme

As stated earlier under floating condition, the battery charger has
an output voltage almost equal to the rated voltage of the load. For
boost charging, the output voltage of the charger has to be
increased to about 2.65 volts per cell in order to drive the required
boost charging current into the battery. Unless special measures
are taken, the load also can be subjected to higher voltage during
this operation and the equipment constituting the load can get
damaged. The various methods for boost charging of battery
without applications of higher than the rated voltage of the load are
described below briefly.
1.7.2
Two battery charger scheme :

This scheme though simple is expensive. There are two sets of
batteries and charger. One set is always kept floating at the rated
with the battery receiving the small float charge current and the
station load being met by the float charger. The other set is also
kept floating.
A recent improvement is the scheme in which two chargers, two
batteries and two trip coils are used. Normally both the chargers
are in use and when a boost charge is required, the load is
connected to one set and the other set is put on boost charge.
When A.C. supply is available and both the chargers and battery
are in float mode the two DC systems (battery, battery charger and
distribution board) are independent of each other and isolated
through an isolating switch. If the battery connected across the
load gets depleted due to heavy load demand, the load is
connected to the other battery and charger by the DC change over
contactor provided and the depleted battery is boost charged
without the load. The scheme is generally adopted only when
provision of two batteries and two chargers is justified from the
consideration of reliability.
1.7.3
End cell cutting scheme :

In this scheme (Fig.1.2) the charger is connected across the
battery in the normal way, but the load is connected through
contactor 'S' by which a specific number of cells can be switched in
or out.
Under float charger condition the contactor
'S' is
in
position-I and full charger voltage is applied to the load. For boost
charging, the charger voltage is suitably increased and contactor 'S'
is put in position-2. In this position full boost charger voltage is
applied to the battery with a reduced number of cells connected
across the load. The number of cells cut off from the load called
'end cells' are so selected that under this condition only the
rated voltage appears across the load. The contactor is suitable for
make - before - break operation and is provided with suitable
resistances between the successive positions to prevent short. The
boost charge current is 'Q'
Amps and the load current is 'C' Amps, then the end cells receive a
current equal to (C+Q) Amps. Thus the end cells are charged at a
higher rate due to which these cells are subjected to gassing and
over - heating.
This scheme was extensively adopted earlier but has now been
replaced by the scheme described below.
1.7.4
Separate boost and float charger scheme with blocking

diodes:
This scheme is shown in Fig.1.1. Under float charge condition the
boost charger switch 'S' is in the 'off' position. The coil of contactor
'A' is not energised. In this position, contact 4 of the contactor are
open, but its normally closed contact 4 is closed and the circuit of
dc contactor 'B' the contacts of which are in closed position, is
complete. Thus the battery, the float charger and the load are in
parallel connection. The load current is being supplied by the float
charger which is also sending a small float charge current into the
battery such that the battery is maintained in a fully charged
condition.
If an emergency arises and the ac supply fails, the output of float

charger goes off but the battery is available to the load.
After the emergency is over and the ac supply is restored and it is
desired to boost charge the battery, the boost charger through
contacts 1, 2 and 3 contactor 'A' and a suitable voltage is applied
across the battery and it starts receiving the boost charge current.
Contactor 'A' being in energised position, its normally closed
contact 4 opens and deenergise contactor 'B' thereby opening its
contacts thus the charger. In this position, the high voltage of the
boost charger is not applied to the load which continues to be fed
by the float charger. If during the boost charging operation, the ac
supply fails the contactor 'A' drops, thereby energising contactor 'B'
the contacts of contactor 'B' there upon parallel the battery and the
load. During the infinitely small time involved in the cascade
switching of contactor 'A' and 'B' the load is connected through the
blocking diode across a reduced number of cells which depending
on the degree of recharging can supply upto the nominal system
voltage to the load. If one of the chargers becomes defective, the
remaining healthy charger can still provide the charging facility
even-though it is somewhat restricted and a complete break-down
is obviated. This scheme, however, does not provide a direct
connection between battery and the dc load, as during the failure
of ac supply, the flow of current has to take place through diode
and contacts of the contactor.

1.7.5
Float-cum-Boost charger :
In this scheme, both float and boost charger have thyrister
controlled rectifier bridge. The incoming supply to the three phase
thyristor bridge of float charger is through a three phase double
wound step down transformer. The triggering of thyristor is
controlled by AVR unit which senses feed back from output voltage
and current. These feed back signals are suitably processed and
compared with reference generated in the AVR circuits. The error
is amplified and phase compensated by high gain operational
amplifier and output of final amplifier is fed to the triggering circuit
which controls the output voltage by adjusting the firing angle of
thyristors. The boost charger circuit is almost similar to that of float
charger.
The added feature under this scheme is that boost charger can
operate as a float charger with fully automatic changeover facility,
under designed full float load, in case of failure of float charger.
Some manufacturers offer float-cum-boost charger having
common rectifier and transformers.
1.8
Receipt of Batteries
1.8.1
Checking number of packages received
When the cells and the accessories are received, the total number
of packages received should be first checked and tallied with the

delivery challan.
1.8.2
Un-packing cells
Whenever the cells are supplied in packed condition, un-pack each
case carefully without imparting any damage to the contents of
the package. The cells should be removed carefully by holding
them at the bottom or in a horizontal position. The cells should
never be removed from the packages by holding the terminals,
since this can disturb the group assembly inside. After removing
the cells from the packages, any dust or straw sticking to the cells
should be removed.
1.8.3
Packages containing electrolyte carboys

The Wooden packages containing Electrolyte carboys should
never
be
unpacked.
Till
Electrolyte
is
used
for
battery
commissioning, these carboys have to be kept in the wooden

packages only and handled as such.
Even when Electrolyte is
poured into the cells before commissioning, the same has to be

done by holding the package, without at any time removing the
carboys from the package.
1.9
Storage of Batteries
i)
In case the cells are not required to be commissioned

immediately, they have to be stored in a cool dry place
protected from the sun, rain and dust.
ii)
Every care should be taken in sealing the throw-away plugs

using adhesive tapes as stated earlier.
iii)
Similarly, the accessories have to be stored without any

damage to them.
iv)
The Electrolyte should be stored in a separate and identified

place in Stores, so that in the event
of any leakage of
Electrolyte, the other materials in the Stores are not

affected.
v)
It is once again stressed that all the items should be stored

only inside the building and never in a temporary shed or in
any open yard. The storage room which should be
preferably on the ground floor should be properly ventilated.
vi)
The cells can be placed horizontally and stacked one above

the other. The bottom most row of the cells so stacked
should not be directly on the floor but separated from
their ground by means of polythene covers or gunny bags.
1.10
Receipt & Storage of Battery Charger

The battery-charger comprises of a separate float charger and a
boost charger or the same can be a combined float-cum boostcharger. From the name plate of the battery charging equipment
one has to ensure, if the DC output voltage available from the
boost charger (or in the
boost mode of the float cum boost
charger) on full load has a range between 1.80 volt and 2.65 volt
per cell. The circuit diagram of the charging equipment has also to
be studied to know what facility the boost charger (or charger in
boost mode as the case may be ) has for continuously increasing
the voltage from 1.80 to 2.65 volt per cell. Similarly, the output
current rating of the boost charger should not be less than the
current required for recharging the batteries as furnished in our
battery specifications.
1.11
Electrolyte Preparation
If the battery is supplied with ready mixed acid, it is of specific
gravity 1.190 approximately and the same conforms to IS:266. If
the acid is procured separately, one has to ensure the specific
gravity of 1.190 and also specification of acid to conform to IS:266.
Where the purchaser procures concentrated
sulphuric Acid, he
has to ensure the conformity of the same to IS:266, whereafter the

following diluting procedure can be adopted. For dilution, the
distilled water conforming to IS:1069 has to be arranged. For
preparation of approx. 50 litres of Dilute Sulphuric Acid, the
proportion of concentrated sulphuric acid and distilled water will
be as per the following Table:-
For 50 Litres (approx) of Dilute Sulphuric Acid

Specific gravity of
concentrated acid
available
(1)
1.840
1.840
1.840
1.840
Required Specific
gravity of dilute
acid
(2)
1.190
1.180
1.190
1.180
Qty. of water required

in litres
(3)
43.0
43.0
28.4
29.6
Qty. of
concentrated acid
required
(4)
8.6
8.0
22.5
21.3
When acid and water are mixed, there is a contraction in volume. Hence,
columns (3) and (4) total to more than 50 litres. While preparing the Dilute Acid
solution, one should be careful to add acid to water and not vice versa. This
dilute sulphuric acid can be prepared in a clean Lead Lined wooden tank or
plastic, glass or lead rod. After mixing, the solution should be allowed to cool
over night and the specific gravity and temperature should be read by means of
Hydrometer and Thermometer respectively. If the required specific gravity is not
obtained, add acid or distilled water, as the case my be till the correct specific
gravity is obtained.
1.12
Erection and commissioning

1.12.1
Installation
i)
Battery-charger-installation
The battery-charger has to be installed at a suitable place
fully partitioned from the battery
room
to protect the
charger from the acid fumes.
After placing the battery-charger in the location ear-marked

for the same, check the various components of the battery
charger
with
respective
circuit
diagram
and
general
arrangement drawing supplied. Terminate the AC incoming

cables of the battery charger at the terminal board provided
in the charger. Energise the charger on the AC side and with
the DC output switch of the charger open, test the charger
on no load. The positive and negative terminals of the
battery-charger, which are to be connected to the battery
will have to be tested for ensuring the correctness of the
polarity as marked on the terminal board. Thereafter, the DC
outgoing cables from the battery charger to the battery may
be connected, keeping in view the positive and negative
polarities at either end.
Depending upon the voltage control provided on the charger,
gradually increase the DC output voltage and observe the
DC voltmeter reading to ensure the effectiveness of voltage
control provided.
1.12.2
Battery Installation
i)
Arrange the Wooden stands as per the battery layout

drawing supplied and place underneath the legs of the
stands which are normally PVC sheet. Level the stands
properly.
ii)
Place the cell insulators on the stands at the appropriate

locations and mount the cells on the Cell Insulators, duly
ensuring correctness of levels.
iii)
Arrange the cells on the wooden stands, such that the

positive terminals(s) of any one cell adjoins the negative
terminals(s) of the next cell throughout the battery.
1.13
First charge
i)
Check again the polarity of inter-cell/row/tier connections.

Ensure that all fastening and connections are tight.
ii)
It is of utmost importance that the positive lead of the battery

is connected to the positive terminal of the charger.
The polarity is usually marked near the terminals provided
on the charger. In case of doubt, the voltmeter provided in
the charger can be used to check the polarity of the
terminals. In case the voltmeter is connected before the DC
output switch of the charger, this switch is to be closed, so
that the Voltmeter is able to read the voltage of the battery.
If the deflection is in the positive (clockwise) direction, the
connections are in order. In case of reverse deflection, the
leads should be inter changed and the test repeated as
described above. The AC mains switch of the charger
should remain switched off while taking the polarity test.
After the correct polarity is ascertained, switch off the
DC output switch of the charger.
iii)
Ensure that the voltage control device in the battery charger

is at the minimum position so that when the charger is
switched on, minimum or no current flows into the battery.

Switch on the battery charger. Slowly increase the current to
the value specified below and follow the charging schedule
maintaining the current constant throughout the first charge.
A typical charging cycle may be in the following form.
a)
Charge for 60 hours at 30 Amps.
b)
Rest for 4 hours.
c)
Charge for 40 hours at 30 Amps.
Total input 3000 AH.

iv)
The level of electrolyte may fall slightly during charging.

Maintain the level throughout by adding distilled water.
v)
During the early stages of the first charge, the specific

gravity may fall but after the charging has been in progress
for some time, the specific gravity of the electrolyte will
gradually start rising, reaching a steady value.
vi)
The readings of specific gravity and voltage of each cell

may
be
taken
at
intervals
of
hours
from
the
commencement of charge. After 90 hours of charge, take

hourly readings.
vii)
Towards the end of charge, all cells start gassing freely. The
voltage will reach a final value of 2.50 Volts per cell and the
specific gravity to 1.210+/-0.005. Do not terminate the
charge even if the specific gravity and voltage readings
exceed the above values until the specified ampere hour
input is fed into the battery.

viii)
At no stage during charging, the temperature be allowed to

exceed 50C. If the temperature tends to rise beyond 45C,
reduce the current to one third the value so that the
temperature ceases to rise. However, if at any time, the
current is reduced, the time of charging should be
correspondingly increased so that at the end of charging, the
specified ampere hours input has been up into the cells.
ix)
The charging may be suspended for some time to allow the

cells to cool, provided 50% of the total ampere hour input is
fed. Under no circumstances initial charging be stopped
prior to 50% of the total input is given.
x)
At places where high ambient temperature normally prevails

and where electrolyte temperature limit of 50C would make
charging impossible, it is recommended
that the cells be
filled during night time and charging undertaken during

the night and suspended during the day.
xi)
In case of power shut down or any other unforeseen

exigencies, the initial charging may be interrupted for a
maximum period of 24 hours, provided 50% of the total
ampere hour input is fed in. In such a case, the total time
should be suitably extended to give the specified ampere
hour input to the cells.
xii)
Before completion of initial charge it is necessary that the
specific gravity is adjusted to 1.210+/-0.005 (at 27C). In

order to achieve this specific gravity at the conclusion of
initial charge, it is necessary that this adjustment is done
well in advance, say, during the last 10 hours of charge.
If the specific gravity of electrolyte exceeds 1.215, withdraw
some electrolyte and add distilled
water. If the specific
gravity of the electrolyte is below 1.210, withdraw some

electrolyte and add acid of specific gravity 1.300. While
adjusting the specific gravity, it is necessary to maintain the
level of electrolyte in the cell to the prescribed level as
indicated by the level indicator.
After the addition of distilled water or acid as the case may
be, continue the charge so that water and acid mix
thoroughly.
The final specific gravity of all the cells should be 1.210+/0.005 (at 27C) and the level to the top red mark of the floatguide.
1.14
Capacity test
i)
The battery which has been given the first charge as

detailed above, is allowed to stand on open circuit for not
less than 12 hours and not more than 24 hours. Thereafter
discharge the battery through a variable resistance or
acidulated water load at a constant current of 60 Amps. or
as specified by the manufacturer. The discharge should be

stopped when the closed circuit voltage across the battery
has been to 1.85 x n Volts, where 'n' is the number of cells
in series in the battery or when the voltage across any one
cell has fallen to 1.70 V, whichever is earlier.
ii)
The time hours elapsing between the beginning and the end
of discharge should be taken as the period of discharge.
iii)
On the first discharge, the battery should give not less than
85 per cent of the rated capacity. The rated capacity should
be achieved within three discharge cycles subsequent to
the initial (first) charge.
iv)
Recharge the battery at the constant normal recharge

current of 60 Amps till the cells start gassing at a voltage of
2.35 to 2.4 volts per cell and thereafter the charging current
to the finishing rate of 30 Amps and continue charging at this
current till the voltage of each cell reaches 2.55 V to 2.65
V and the specific gravity to 1.210+/-0.005 and both
remain constant for three consecutive half hourly readings
(at the reference temperature of 27C).
v)
Take two or more such cycles of discharge and charge at

currents specified against serial numbers (i) and (iv) above.
The specific gravity of the electrolyte should always be
adjusted
confirmed.
to
1.210+/-0.005,
before
the
discharge
is
1.15
Recharge
i)
After the capacity test is over as above, the battery has now
to be recharged. This has to be done by adopting the
normal recharge current upto gassing point( static current)
and at reduced recharging current after gassing ( finishing
current) exactly in line with the current values as per 1.13(iv)
mentioned above. After adjusting the specific gravity to be
within 1.210+/-0.005, the fully recharged battery will have to
be floated at 2.16 volts per cell stabilised within 1%. Once it
is ensured that the floating voltage is 2.16 volts 1% per cell,
there is no need to monitor the trickle charging current
passing through the battery.
ii)
If the battery is not to be commissioned immediately and is

to be kept idle for some period, it is essential that the battery
be given an equalising charging every fortnight. The specific
gravity of all the cells should be equalised to the full charged
value. The charge should not take more than 8 hours.
1.16 Field quality plan

The Receipt of Material at site, its Storage, erection, testing and
commissioning of the equipment in this package are to be carried
out in accordance with standards and required quality. For this
purpose a `Field Quality Plan' for this package approved by
Corporate QA & I Department is given to site. In case site does not

get the above in time, they should ask for, get the same and
implement.
The Field Quality Plan consists of the following main items:
i)
Material receipt, inspection at site and storage until erection.
ii)
Erection of the equipment
iii)
Testing, precommissioning
iv)
Commissioning tests and commissioning
GUIDELINES
1.17 Special points with regard to installation of large capacity

stationary cells
i)
These cells being of large size and heavy weight, should be

handled carefully with the aid of a Fork-Lift. To facilitate this,
suitable wooden pallets are provided below each cell.
ii)
After transporting the cells to the battery room, place the

cells alongwith wooden pallets close to the wooden stand
and at the desired position.
iii)
Remove the PVC band (strap).
iv)
Now slowly slide the cell, manually on the wooden stand

taking care that the container does not rub or strike against
hard surface.
v)
Do not handle the cells using terminals pillars.
vi)
Now place the cell in position with proper polarities for

interconnection as per layout drawing.
1.17.1
Throw-away-plugs
Every cell is dispatched duly fitted with the throw-away-plugs, which
cover the vent holes. Since vent plugs and/or vent plug cum level
indicators are dispatched in a separate packing case alongwith
other accessories, the throw-away-plugs have to be discarded only
when the cells are taken up for erection, when the vent holes will
be fitted with vent plugs and/or vent plug cum level indicators.
Till such time, the throw-away-plugs have to be preserved in
position, preferably by fixing adhesive tapes on them for additional
safety.
1.18
Un-packing accessories
The package(s), containing accessories should be un-packed
carefully and the accessories contained therein should be tallied
with the quantities mentioned in the delivery challans. After
checking, the accessories should be preferably placed in the same
packages till they are required for erection and commissioning.
1.19
Preparations before Erection & Commissioning

1.19.1
Battery Room
The Battery Room should be ready in all respects by fulfilling the
following minimum requirements :i)
The walls and the ceiling of the battery room should be well
white washed and should remain clean and dry.
ii)
The flooring of the battery room should be of acid resistant

tiles and materials.
iii)
The battery room should be well lit. There should be no

direct sunlight on the cells.
iv)
Suitable exhaust fans should be fixed in the battery room to

provide a minimum of six air changes per hour. The exhaust
fans should be suitably distributed and placed on the

wall,the outside of which should be open to the atmosphere.
Equally sufficient air-inlet should be provided to the battery
room to prevent any negative pressure developing in the
room. Necessarily, blowers are to be provided to maintain
sufficient air inlet into the room. Entrance door should never
be kept closed, which will lead to a negative pressure
developing in the battery room due to the continuous
operation of the exhaust fans.
v)
The inlet air should be free from effluents such as chlorine,

acetic acid or any such gasses being
produced in the
vicinity. Air filters at the air inlet points should be provided

so that the extraneous material like coal dust, laden in the
air, are filtered.
1.20
Precautions during Battery Installation

i)
Where cells are to be placed in two rows and/or two-tiers,

ensure that the positive terminal(s) of the end cell of one-row
(or one tier as the case may be) is connected to the negative
terminal(s) of the end cell or other row, or other tier as the
case may be. The connection between two-rows or tiers are
made with the help of inter-row or inter-tier connectors
supplied, wherever specified in the scope of supply (In
case of terraced wooden stands, the inter-row connections
should be by means of a cable).

ii)
Lead plated copper plates are supplied, wherever the scope

of supply provides for the same, which are called as the
End Take-Offs. Normally, two End Take-Offs are supplied,
one for the positive and the other for the negative terminal of
the battery bank as a whole. (A third End Take-Off is also
supplied, where an intermediate cell from the battery bank
has to be tapped off, as a part of battery-cum-charger
scheme). It may be noted only batteries of 200 AH capacity
and above are supplied with separate End-Take-Offs,
whereas batteries of capacities lower than 200 AH, the
end terminal connections have to be made directly on the
battery terminals.
Drill a hole at one end of the End-Take-Off plate to suit the
diameter of the lug of the external cable, terminating on the
Battery bank. The other end of the End-Take-Off copper
plate, is to be bolted to the battery terminal.
iii)
Wipe out any dust collected on the top of the cover of the
cells by means of a clean duster. Smear a little Petroleum
Jelly on the threads, bolting faces and
the
bolt holes,
before bolting up the various connectors. Connect the intercell/inter-row/interier connectors sufficiently tight, to avoid
any loose connections and again smear petroleum jelly over
the nuts, bolt-heads and washers. Even the exposed
surfaces of inter-cell/inter-row/inter/tier connectors have also

to be smeared with petroleum jelly.
iv)
Connect external cables from the battery charger, to the

respective end terminals of the battery bank, once again
ensuring the polarities. The positive terminal of the charger
has to be connected to positive of the battery bank and
similar is the case of negative to negative connections.
Wherever a tapping has to be taken from an intermediate
point of the battery bank, these tappings have to be taken
from an intermediate point of the battery bank. These
tappings have to be counted from the negative terminal of
the end cell of the battery bank, which is taken as the first
cell of the battery. In other words the negative terminal of
the first cell is the negative of the battery bank and the
positive terminal of the last cell is the positive of the battery
bank.
v)
While making connections care should be taken not to

remove
the
throwaway plugs, so that, no
fastening
material falls into the cell. Also, no metal tools should be left
on top of the cells at any time.
1.21
Rated Ampere-Hour (AH) capacity

i)
The energy storage capacity of a battery is expressed in

Ampere -Hours which is the product of current in amperes
and the number of hours for which
the
same can be
usefully delivered by the battery.

ii)
The ampere-hour capacity of a battery of lead acid cells

varies with the rate of discharge. The capacity is more at
slower rates of discharge and less at higher rates of
discharge. Hence there is need for adopting a standard
reference rate of discharge.
Table 2, 3 & 4 indicate the effective capacity of battery
for different rates of discharge and the corresponding final
voltage per cell as specified in the relevant ISS.
TABLE - 3
Capacities and Final Cell Voltages at various Rates of
Discharge at 27C (Tubular Cells)
-------------------------------------------------------------------------------------------------------------------------Sl.
Period of
Effective capacity
Final Voltage
No.
discharge
expressed as percentage
per cell
of the standard capacity
(Volts)
corresponding to
discharge rate
--------------------------------------------------------------------------------------------------------------------------1
2
3
4
---------------------------------------------------------------------------------------------------------------------------
1.
10
100.00
1.85
2.
97.90
1.84
3.
95.00
1.84
4.
91.70
1.83
5.
87.90
1.83
6.
83.30
1.82
7.
78.20
1.81
8.
71.70
1.80
9.
63.30
1.78
10.
1
50.00
1.75
---------------------------------------------------------------------------------------------------------------------------
TABLE -4
Capacities and Discharge Current at 27C of High Discharge Performance
Cells at Various Rates of Discharge (Plante Cells)
-------------------------------------------------------------------------------------------------------------------------------Period of Discharge Ah Capacities as Percentage
Discharge Current as
Cell end
(hours)
of Standard Rating
----------------------------
----------------------------------------
percentage of Standard
Rating
---------------------------------
8 & 25
Ah Plates
8 & 25
Ah plates
(percent)
10 Ah
Plates
(percent)
(percent)
Voltage
(Volts)
---------------
100 Ah
Plates
(percent)
-------------------------------------------------------------------------------------------------------------------------------1.
2.
3.
4.
5.
6.
--------------------------------------------------------------------------------------------------------------------------------
10
100.0
100.0
10.0
10.0
1.85
98.0
98.0
10.9
11.0
1.84
95.0
97.1
12.0
12.1
1.84
93.3
95.1
13.3
13.6
1.83
91.0
93.0
15.2
15.5
1.83
88.0
90.0
17.6
18.0
1.82
84.0
86.2
21.0
21.5
1.81
80.0
81.1
26.6
27.0
1.80
73.0
73.8
36.5
36.9
1.78
1
60.0
60.0
60.0
60.0
1.75
--------------------------------------------------------------------------------------------------------------------------------
TABLE -5
Capacities and Final cell voltage at various rates of
discharge at 27C (Flat Pasted Cells)
-------------------------------------------------------------------------------------------------------------------------------Discharge
Ah Capacities as Percentage of
Cell end
Rate
Standard 10-Hours Rating
Voltage
(hours)
(percent)
(Volts)
--------------------------------------------------------------------------------------------------------------------------------
1.
2.
3.
--------------------------------------------------------------------------------------------------------------------------------
10
100.0
1.85
98.0
1.84
95.0
1.84
91.7
1.83
87.9
1.83
83.3
1.82
78.2
1.81
71.7
1.80
63.3
1.78
1
50.0
1.75
-----------------------------------------------------------------------------------------------------------1.22 Initial filling of electrolyte
i)
Remove the throw-away plugs provided on the holes of the

cover and fix the vent plug cum level indicator in one hole,
wherever the cells have two holes, one for vent plug and
other for vent
plug
cum
level indicator. This generally
applies to cells of capacities 100 AH and above.

ii)
Lift the electrolyte carboys containing dilute sulphuric acid

(supplied ready mixed or prepared previously, as the case
may be) alongwith the packing cases intact and pour the
electrolyte carefully into the jugs supplied, from where pour
the electrolyte into the cells through the vent hole with the
help of a funnel.
iii)
The level of electrolyte in each cell should be adjusted to

correspond to the top red-mark on the float-guide.
iv)
The bottom red-mark indicates the minimum level
below
which electrolyte should not go.

v)
In case of cell of capacities from 20 AH to 80 AH, generally

there in no separate vent plug but there only one integral
vent plug cum level indicator. In these cells the electrolyte
has to be poured through the vent holes, whereafter the vent
plug cum level indicator has to be fixed, to notice the level
of electrolyte in the level indicator. Two or three trial
operations of filling the electrolyte
through the vent hole
available and checking the level after fixing the vent plug
cum level indicator may be required in these cells of 20 AH
to 80 AH.
vi)
Fix the vent plugs on to the cells but do not tighten.
vii)
After filling-in with electrolyte, leave the cells idle, for a

period not less than 12 hours and not more than 24 hours,
until the electrolyte temperature falls down from the initial

level. The plates will absorb the electrolyte causing a drop in
the electrolyte level. Restore the electrolyte level by adding
some more electrolyte of the same specific gravity used
earlier. Again replace the vent plugs without tightening. The
battery is now ready for first charge.
1.23 Caution
When working with acid, dilute or concentrated, use protective
goggles, rubber gloves, and aprons.
In case, acid splashes on
the garments, remove the same immediately, neutralise the spot

with 5 to 10% Ammonia or Soda solution and wash thoroughly in
water. In case of acid splash on the skin or other parts of the body,
flush with a large quantity of water and seek immediate medical
aid.
1.24 Important instructions
i)
Smoking or use of a naked flame in the battery room should

be strictly prohibited.
ii)
Ensure correct polarity between adjacent cells and between

the battery and the charging source. Charging the cell or
battery in the wrong direction will ruin it.
iii)
Never make the specific gravity adjustment on a cell which

does not gas freely on charge. Report the matter
immediately to the manufacturer.

iv)
Use calibrated meters for measuring current, cell voltage,

specific gravity and temperature.
v)
The Performance of a Battery during its service depends

on to a great extent how completely the initial or first
charge is carried out. Never therefore, terminate the charge
until the specific ampere hour input is put into the battery
even though the cells may show constant or higher specific
gravity and voltage readings, even before completion of full
Ampere-Hour input.
1.25 Battery capacity

The battery capacity can then be calculated in the following
manner:
i)
Classify all loads duration wise after converting them into

amperes corresponding to 2 volts per cell and applying a
reasonable diversity factor to the indicating lamp load.
ii)
Multiply the current due to each load and their respective

duration to arrive at ampere hour capacities.
iii)
Correct these capacities for rated electrolyte temperature of

27C corresponding to the lowest actual site temperature.
iv)
Convert the Ah capacities thus determined with the help of

Table-2, into capacities referred to the standard 10-hour
rate of discharge. Add those capacities to arrive at the total
capacity referred to 10-hour rate of discharge.

v)
Determine the Ah actually used in each discharge duration

and find out the residual capacity. Reduce the residual
capacity left after first discharge duration from that
determined for the next
discharge duration and continue
this process for the discharge durations. Add the resulting

capacity figures to arrive at the total battery capacity.
vi)
To account for ageing of battery multiply the load expected

at the end of its service life by 1.25. As the initial capacity of
battery rises after some charge-discharge cycles or after
some years of float operation, capacity of the battery need
be 90 to 95% of the capacity determined above.
vii)
To account for unforeseen additions to the DC system and

less than optimum operating conditions of the battery due
to improper maintenance, the capacity determined above
is further increased suitably, by 10-15%.
viii)
Capacity of the battery is fixed equal to that commercially

available next higher to the capacity calculated in (vii).
1.26 Calculation of battery capacity

i)
Capacity
of
battery
required
depends
on
the
magnitudes and durations of the various loads, the battery is

required to feed and the allowable end voltage. Although for
the sake of accuracy the load cycle on a battery should be
expressed as a diagram showing maximum current required

for each interval of time in proper sequence for determining
the battery capacity, the load cycle in which the heaviest
load is assumed to occur in the last part of the cycle is
recommended for determining the battery capacity as it
results in a higher capacity.
ii)
The loads on the control bus can be classified into the

following categories for determining battery capacity :
a)
Momentary loads such as those due to operation of

switchgear (trip coils, closing coils etc.)
b)
Steady and continuous loads - These are due to indicating lamps, holding coils of relays, interlock devices
and other supervisory control equipments.
c)
iii)
Emergency light load.
The Momentary Loads mentioned at (a) normally cause a

negligible drain on the station battery as at the most only
one or two circuit breakers may operate at a time and the
duration of this type of load is in milliseconds. Therefore, this
type of loads can be safely ignored. However at the
substations where busbar protection is installed, a large
number
of circuit breakers may operate simultaneously
followed by an A.C. Supply failure. For such stations,

tripping and closing of all circuit breakers has to be
considered.
iv)
As regards the duration for which the battery
should be
capable to supply the other loads, the practices vary, widely

as can be seen below :
-
Steady and continuous load :

a)
3 to 12 hours at attended stations.
b)
24 hours at unattended stations.
Emergency light load : 1 to 12 hours

For installations of the attended type the following
durations may be assumed for computation of battery
capacity
Where standby
battery is
provided
------------
Where standby
battery is not
provided
-------------
Steady and continuous load :
3 hours
6 hours
Emergency light loads :
1 hour
2 hours
v)
Although the actual durations for which the momentary loads

of circuit breaker trip coils and closing coils imposed are in
milliseconds only, a duration of one minute should be
adopted as the voltage drop caused by such loads is almost
of the same order as caused by loads lasting for one minute.
1.27 Factors affecting battery life

1.27.1
Overcharging
Charging a battery greatly in excess of what is required is harmful
in several ways, as:

i)
It decomposes water of electrolyte into hydrogen and

oxygen gas. Gas bubbles tend to wash active material from
the plates and carry moisture and acid from the cells as a
fine mist.
ii)
Decomposition of water leaves acid more concentrated.

Concentrated acid is harmful to separators and negative
plate material at high temperatures over a prolonged period
of time, charging the separators and making the negative
material sandy and granular.
iii)
High internal heat is created, which accelerates corrosion of

positive plate grids and damages separators and negative
plates. Also, containers may be softened and distorted and
sealing compound displaced.
iv)
Overcharging alone or in combination with a previous

condition of undercharging may cause severe buckling and
warping of positive plates in accompanying perforation of
separators.
It may cause damage by corrosion to cradle, cables and
other vital electrical and engine parts by forcing liquid from
the cells if charge rates are excessive.
1.27.2
Undercharging
i)
A battery appeared with insufficient charge ever a long

period of time may develop a type of sulphate in the plates
which is dense, hard and crystaline and which cannot be

electronically concerted to normal active material again.
Such lead sulphate being less dense than the active
material from which it was formed will set up strains in the
positive plates so that distortion or bowing of the plates,
called buckling, may result. Buckling will be produced,
especially if the sulphated battery is subjected to sudden
prolonged overcharging.Severely buckled plates will pinch
the separators at the plate corners or chafe the center of
the separators. This may result in perforations of an
unprotected separator and develop a short circuit of the cell.
ii)
A battery operated in an uncharged conditions is not only

unable to deliver full power but is liable to freeze during
severe winter weather.
iii)
Lead Sulphate formed on the plates during discharge is

relatively insoluable as long as the specific gravity of
electrolyte is kept above 1.125 Sp.Gr. but if allowed to drop
much below this value the lead sulphate becomes
increasingly
soluuable
and,
aided
by
temperature
flucturations of the electrolyte, may migrate over a

considerable period of time into
the pores of
the
separators and deeposit as a shite crystalline mass.

Subsequent charging may concert these crystaline deposits
to
filamentous
metallic lead
which
may "short" the
positive
and
separators
negative plates through the areas of the
affected. These small shorts may cause a
condition of low cell voltage when the battery is charged.
1.27.3
Lack of Water
Water is one of ice four essential chemicals of a lead-acid storage
battery and under normal conditions of operation is the only
component of the battery which is lost as the result of charging. It
should be replaced as soon as the liquid level falls to the top of the
separators. If water is not replaced, and the plats are soon
exposed, the acid will reach a dangerously high concentration that
may char and disintegrate the separators and may permanently
sulphate and impair the performance of the plates
1.28
Being conversant with the accessories

i)
Hydrometer
Acquaint yourself with the syringe type Hydrometer supplied,
by taking some sample readings of the electrolyte. Since
electrolyte specific gravity varies with the temperature, any
specific gravity reading from the Hydrometer should not be
used as it is, but the same should be corrected to 27. If the
electrolyte temperature is above 27, add to the observed
specific gravity reading, 0.0007 for every 1C, above 27C.
Similarly, if the electrolyte temperature is below 27C,
subtract from the observed specific gravity reading, 0.0007

for every 1C. below 27C.
ii)
Thermometer
The specific gravity correction scale is incorporated in the
Thermometer itself. The correction scale readily gives what
correction of specific gravity to be applied, for different
temperatures.
iii)
Center zero voltmeter

The centre zero voltmeter is of range 3-0-3 volt for reading
any one cell voltage. The prods of the voltmeter should be
made to make a good contact on positive and negative
terminals of a cell so that the voltmeter will show the cell
voltage reading.
CHECK FORMAT
1.
2.
Materials received checked for their quantity,

quality, correctness and identification marks as
per the delivery challan/ packing list etc.
YES/NO
All the materials jointly inspected with

supplier and erection agency for damage.
YES/NO
3.
All materials stored properly in such a

way that retrieving of required materials
is easy.
4.
In case the store building is not ready, the

equipment stored indoor otherwise it covered
with water proof tarpaulins.
YES/NO
Material record enterde in the proper stock

registers and duly signed by the concerned
personnel.
YES/NO
Packs stored in a cool dry place protected

from the sun, rain and dust.
YES/NO
Un-packing of each case done carefully

without imparting any damage to the contents
of the package.
YES/NO
While preparing the Dilute Acid solution,

care has been taken to add acid to water
and not vice versa.
YES/NO
After mixing & cooling over night the specific

gravity and temperature read by means of
Hydrometer and Thermometer respectively.
YES/NO
Battery tested for ensuring the correctness

of the polarity as marked on the terminal
board.
YES/NO
Care taken not to handle the cells using

terminals pillars.
YES/NO
YES/NO
5.
6.
7.
8.
9.
10.
11.
12.
Throw-away-plugs preserved in position,

preferably by fixing adhesive tapes on
them for additional safety.
YES/NO
If walls and the ceiling of the battery room

are well white washed, clean and dry.
YES/NO
Flooring of the battery room is of acid

resistant tiles and materials.
YES/NO
15.
If battery room is well lit.
YES/NO
16.
Cells are exposed to direct sunlight.
YES/NO
13.
14.
17.
18.
Suitable exhaust fans fixed in the battery room.
YES/NO
Necessary, blowers provided to maintain

sufficient air inlet into the room.
YES/NO
19. Cells are kept in a wooden stand and properly

arranged.
YES/NO
20.
Level of stands and the cells is checked.
YES/NO
21.
No metal tools left on top of the cells .

YES/NO
Level of electrolyte in each cell adjusted
to correspond to the top red-mark on the
float-guide.
YES/NO
For measuring current, cell voltage, specific

gravity and temperature calibrated meters are
being used.
YES/NO
When working with acid, dilute or concentrated,

use of protective goggles, rubber gloves and
aprons made.
YES/NO
Battery-charger has been installed at a suitable

place fully partitioned from the battery room to
protect the charger from the acid fumes.
YES/NO
26.
Battery charger has been kept in a levelled place.
YES/NO
27.
Various components of the battery charger

checked with respective circuit diagram and
general arrangement drawing supplied.
YES/NO
22.
23.
24.
25.
28.
Charger has been tested on no load.
YES/NO
29.
Positive and negative terminals of the battery

charger, which are to be connected to the battery
tested for ensuring the correctness of the polarity
as marked on the terminal board.
YES/NO
Positive lead of the battery is connected to the

positive terminal of the charger
YES/NO
31.
Battery recharged after the capacity test is over
YES/NO
32.
Charging has been terminated after the specific

ampere Hour input is put into the battery
YES/NO
30.
________________________________________________________________
CHAPTER
TWO
________________________________________________________________
STATION LIGHTING
2.0
Scope of work in a Substation Lighting Contract

The scope of work in atypical substation Lighting Package
comprises of design, engineering, supply, installation, testing and
commissioning of various lighting fixtures complete with lamps,
supports ad accessories, ceiling fans complete with regulators &
accessories, lighting panels, lighting poles complete with
distribution boxes, galvanised frigid steel conduits, lighting wires,
receptacles, switchboards, switches junction boxes, pull out boxes
complete with accessories, lighting transformer etc. It is however
mentioned here that the Township Lighting works Package which is a site
package now is excluded from the scope of S / Stn. Lighting Contract.
2.1
Categories of Substation Lighting

In substation the categories of lighting system can be described in number
of ways
i)
Switchyard lighting
ii)
Control room lighting
(i)
AC Normal Lighting
This includes street lighting and flood / spot lighting from towers. In this
AC light is connected to AC lighting panels. All the lights connected to
the AC lighting system in different areas are connected to the main
lighting distribution boards.
(ii)
AC emergency Lighting
This system is available in control room building, switchyard & D.G.

building. AC lighting load is connected to this system which is normally
ON. The lighting panes of this system are connected to the emergency
lighting board which is fed form diesel generator during the emergency.
(iii)
D.C. Lighting
This system is provided both indoor as well as at outdoor locations which

are of high importance like in the control room near the panels.
2.2
Minimum lux levels

The minimum lux levels to be maintained in the different areas both
indoor and outdoor in a typical 400 / 220 KV substation are
Sl. No. Area
Lux
(i)
Control Room
350
(ii)
PLCC Room.
300
(iii)
LT Room
150
(iv)
Charger Room
150
(v)
Cable Gallery
150
(vi)
Heating Plant
100
vii)
Battery Room
100
viii)
Computer Room 300
ix)
Entrance lobby
x)
Corridor & landing
150
xi)
Conference & display
300
xii)
Rest Room250
xiii)
AHU Room
xiv)
DG Set Building 150
xv)
Fire Fighting Pump House
xvi)
Switchyard
150
100
150
50 lux on Main
Equipment 20 lux on
Gen. Equipments.
2.3
Distribution scheme of lighting

The lighting scheme consists of lighting transformers of 1:1 ratio
providing isolation between lighting loads and other loads. Typically there
are three lighting transformers ((415 / 415 V + - 10% KVA dry
transformers). To the lighting distribution panel (1 & 2) incomer supply is
fed from station emergency Supply panel in case of failure of normal
supply. These lighting transformers are used to control the single phase
AC supply of 230 V. for lamps, chokes, and ignitors of light fittings. The
above fittings will last longer if the voltage is controlled within limits. The
three phase 415 V AC supply will generally have steady output voltage as
the LT Transformers are not fully loaded. Hence, single phase output
voltage will be around 240 V. The output Voltage will be low around 200
V due to the drop in 33 / 11KV SEB supply due to over loading. Hence a
lighting transformer 415 / 415 + 10% is required to maintain the single

phase AC voltage to 220 V, irrespective high / low input 3 phase voltage.
The lighting transformers are also introduced to bring down fault current
level as the lighting transformer is of two winding type.
2.4
DC Lighting
In case AC supply main / emergency fails, DC lighting is provided in
important locations, in control room building, Fire fighting pump House
and DG Set Building. These are incandescent bulbs and are supplied with
220 V DC supply from station batteries. The control is through a main
isolating switch, auto switchover contractor, fuses and individual control
switches which facilitates switching on of DC lights. The DC lights can be
switched on during nights only by providing L&T make TSQ 100 timer
which switches on DC supply to DC lighting during night hours only.
2.5
Receipt of materials at site

Following major equipments / items and materials that comprise in the S /
S lighting contract are received at site.
2.6
i)
Lighting transformers
ii)
Reflectors
iii)
Lamp holders
iv)
Ballasts
v)
Capacitors
vi)
Lamps
vii)
Receptacles
viii)
Switch & Switch Boards
ix)
Conduit & Conduiting Boards
x)
Junction Boxes
xi)
Terminal Blocks
xii)
Lighting Panels
xiii)
PVC wires & Earthing items
xiv)
Lighting poles & fixtures
xv)
Portable Emergency Lights etc.
Inspection of materials
All the materials are to be jointly inspected with supplier and erection
agency. This inspection is required to check the materials received for
their quantity, quality, correctness and identification marks as per the

delivery challan / packing list etc. One should go for checking the
following parameters:
i)
Despatch documents such as RR, LR, MICC, Gate Pass, Packing

List etc.
ii)
Quantity with the delivery challan, packing list, BOQ etc. and any
shortages should be recorded.
iii)
Any physical damage should be brought to the notice of supplier.
iv)
Identification marks should be checked form the MICC
v)
Inspection of the Panel. The meters, relays, switches mounted on

the panel must be intact.
vi)
In case of spares, check for

a) Their physical damage
b) For their operation
c) Genuineness of spares especially filters, gaskets etc.
2.7
Storage:
The erection agency must be provided with space for making indoor stores
cum office and for outdoor storage if provisional space for indoor stores is
not available. All materials are to be stored properly indoor. They should
be stored in such a way that retrieving of required material is easy.
Maintenance of proper stock registers by the erection agency is to be
checked at least once in a week by duly counter singing the register.
Proper care has to be taken to prevent the entry of water / moisture inside
the items if stored outdoor. As some of the items / materials may be prone
to rusting both inside and outside.
2.8
Erection:
The erection should be carried out as per the specified installation

instructions and approved drawings. The various equipments should be
installed, tested and commissioned in a neat, workmen ship manner so that
it is level, plumb square and properly aligned and oriented. Tolerances are
established in the approved manufacturers drawings or as stipulated in the
technical specifications. Necessary care should be exercised in handling to
avoid the distortion of structures, the marring of finish or damaging of
delicate instruments or other electrical parts. All welds, bolt holes, conduit
entry holes etc. made during installation should be wire brushed and
touched up with metal primer. The various sub activities in a lighting
package contract are Fixing of Conduits
i)
Wiring
ii)
Panels
iii)
Receptacles
iv)
Lighting Wires
v)
Flood Lights
vi)
Street Light Poles
vii)
Switch Boards
viii)
Junction Boxes
ix)
Emergency Portable Lighting Fixtures
x)
Cabling
xi)
Earthing / Grounding
xii)
Measurement and taking over
The above item / activities are detailed below:

2.8.1
2.8.2
Fixing of conduits
i)
Each piece of conduit should be straight, free form blisters and

other defects and furnished in standard lengths as per specification
and threaded at both ends. The manufacturers name should be
stamped on each piece which should be checked.
ii)
Conduit routes should be planned in such a way so that the

minimum crossings are achieved.
iii)
The routes should be selected in such a way so that conduit plans

can be optimised.
iv)
All the surface Conduit should be run under the ceiling and in the
wall just below the ceiling.
v)
Conduits should be run straight.
vi)
Conduits should be run on a level surface.
vii)
Conduits should be fixed on saddles.
viii)
For fixing the saddles the drilling should be done using a good
hand-drilling machine with concrete drill bit.
Lighting wires
i)
Wiring should be taken up after completing the conduit fixing.
ii)
Wiring should be carried out by PVC wires in conduits.
iii)
All wires in a conduit should be drawn simultaneously.
iv)
Wires should not be pulled through more than two equivalent 90

deg. Bends in a single conduit run. Where required, suitable
junction boxes should be used.
v)
Wiring should be spliced only at junction boxes with approved
type terminal strip.
2.8.3
vi)
For lighting fixtures, connection should be teed off through

suitable round conduit or junction box, so that the connection can
be attended without taking down the fixture.
vii)
For vertical run of wires in conduit, wires should be suitably

supported by means of wooden / hard rubber plugs at each pull /
junction box.
viii)
Separate neutral wires should be provided for each circuit
ix)
AC and DC wiring should not run through the same conduit.
x)
The wires should be colour coded as follows:

:
Red for R Phase
Yellow for Y Phase
Blue for B Phase
Black for Neutral
White for DC (Positive)
Grey for DC (Negative)
xi)
The wiring should be done as per the circuits given in the approved
drawings
xii)
After completion of wiring, works site should be cleared for other

works like Aircondition ducting, Smoke Alarm work of fire
fighting etc.
Panels
i)
Panels should be outdoor type / indoor type as per requirements.
ii)
All doors, removable covers and plates should be gasketed all

around with neoprene gaskets of the specified material.
iii)
Each panel should have caution notice fixed on it.
iv)
Each panel should be provided with a circuit directory plate

(anodised aluminum with the inscriptions indelibly etched on the
plate / or as mentioned in the specification) which should be fitted
on the inside of the door.
v)
Each lighting panel should be provided with one no. ON

indicating lamp for each phase alongwith fuses.
vi)
Panels should be mounded away from the windows and doors.
vii)
Sufficient working space should be provided in a panel.
viii)
Panel should be mounted as per the drawings. However, the

necessary shifting of panels (to suit the site requirements) should
be carried out in consultation with the Engineering department.
ix)
2.8.4
2.8.5
2.8.6
2.8.7
Necessary foundations / supporting structures for all outdoor type

lighting panels and necessary supporting structures for indoor
lighting panels should be provided.
Receptacles
i)
Receptacles should be provided near those equipments where

electric supply may be required.
ii)
Receptacles should be fixed at the places as mentioned in the

drawings keeping in mind that these should be near the location
were the supply may be required.
iii)
In the outdoor area the location of the receptacle should be chosen

carefully based on the power supply requirements at that point (like
welding transformers, blowers etc.)
iv)
Receptacles should be equally spared through out the switchyard

area
Flood lights
i)
Flood Lights should be installed on lightning masts / switchyard

structures wherever required at site.
ii)
Fixtures should be mounted on the Galvanised Mast making use of

shop provided holes or by suitable clamps. No cutting or drilling of
galvanised structure is permitted.
iii)
The mounting of assembled fittings and installation of necessary

cables is in the scope of supplier.
Street lighting poles

i)
Street lighting poles should be installed as per the approved

drawings during detailed engineering.
ii)
Street lighting poles work involves excavation, shifting poles,

erection of poles, welding of earthing plate to grid earth mat of
switchyard, alignment and concreting.
iii)
Excavation should be performed upto the required depth. Such

shuttering & shoring should be done as may third be necessary for
protection of the work.
iv)
The level and the line of lighting poles should be Checked and kept
same for all poles.
v)
After final finishing and coping the site should be cleared.
Emergency portable Lighting Fixtures

i)
This should be provided in control room and those places where

illumination is required in case of emergency / total failure.
ii)
The portable fixtures have a built in battery rated for specified

hours, battery chargers and solid state inverters. These should be of
approved make.
2.8.8
2.8.9
2.8.10
2.8.11
2.8.12
iii)
The portable fixtures should be of a single unit, completely

tropicalised and suitable for prolonged use with on maintenance.
iv)
The portable fixtures and necessary supporting brackets of

galvanised steel suitable for wall / column mounting are supplied
by the supplier.
v)
The portable fixture should come up automatically in the event of

failure of normal supply.
Switchboard
i)
Switch board / boxes located in office / building areas should be

flush mounted type of brick wall with only the switch knob
projecting outside.
ii)
Switch board / boxes should have conduit knock outs on all the
sides. Adequate provision should be made for ventilation of these
boxes.
Junction boxes
i)
The junction boxes should be mounted on walls, columns, lighting

poles structures etc. The supplies of brackets, bolts, nuts and
screws required for the erection are made by the supplier.
ii)
The junction boxes should be complete with conduit knockouts /

threaded nuts and provided with terminal strips as specified.
iii)
The junction boxes should be weather proof type with gaskets

conforming to specifications.
Cabling
i)
Cabling should be done as per the approved a cable schedules.
ii)
Proper double compression glands and lugs should be terminated

in panels / sub-lighting panels.
Earthing / grounding
i)
All lighting panels, junction boxes , fixtures, conduits etc. are

grounded in compliance with the provision of I.E. Rules.
ii)
Ground connections should be made from nearest available station

ground grid. All connections to ground grid are done by arc
welding.
iii)
Lighting panels are directly connected to ground grid by G.S. flats

of specified numbers and size.
iv)
All lightning poles are earthed as per approved drawings and

specification.
Testing and commissioning

(i)
Lighting transformers should be tested for

a)
Ratio test (at each tap)
(ii)
2.8.13
b)
Insulation resistance
c)
Terminal tightness
Main checks for various equipments / fixtures should include

a)
Phase control
b)
Current in each phase
c)
d)
Terminal tightness
e)
Lux levels in all the areas and other test as per approved
filed quality plan.
f)
Healthiness of all the lamps should also be checked.
Measurement of conduit / wire

i)
Measurement of conduit length / PVC wire length should be

carried out room / area wise. Moreover in a room it should be
measured circuit wise.
ii)
Measurement of lux levels in the different zones / areas should be

done and compared with the specification.
2.9
Field Quality Plan

The Receipt of Material at site, its storage, erection, testing and

commissioning of the equipment in this package are to be carried out in
accordance with standards and required quality. For this purpose a Field
Quality Plan for this package approved by Corporate QA & I Department
is given to site. In case site does not get the above in time, they should ask
for, get the same and implement.
i)
Material receipt, inspection at site and storage until erection.
ii)
Erection of the equipment
iii)
Testing, precommissioning
iv)
Commissioning tests and commissioning.
GUIDELINES
2.10
Constructional features
2.10.1
2.10.2
Reflectors/Lamps/Conduits
i)
The reflectors should be manufactured from sheet steel or

aluminum as applicable of not less than 22 SWG thickness. They
should be securely fixed to the captive type.
ii)
The fluorescent lamps should be Day-light-colour type unless

otherwise specified and should also be provided with features to
avoid blackening of lamp ends.
iii)
Mercury vapour lamps, sodium vapour lamps should be colour

corrected type with screwed caps.
iv)
The lamps should be suitable for use in any position. Restrictions,

if any, should be clearly stated.
v)
The lamps should be capable of withstanding small vibrations and

the connections at lead-in wires and filaments / electrodes should
not break under such circumstances.
vi)
Each piece of conduit should be straight, free form blisters and

other defects, and furnished in standard length of 3.0 meters
threaded at both ends. The manufacturers name be stamped on
each piece.
vii)
Each terminal should be suitable for terminating upto2 Nos., 10 sq.

mm./ specified size stranded aluminum conductors without any
damage to the conductors or any looseness of connections.
Terminal strips provided in street lighting poles should be suitable
for terminating upto 2 nos. 4C x 16 sq . mm. / specified size
aluminum cables.
viii)
Switch fuse units with neutral link and outgoing miniature circuit
breakers as per schedule of Quantities should be produced.
Panels
i)
Panels should be sheet steel enclosed and should be dust, weather

and vermin proof; Sheet steel used should be of thickness not less
than 2 mm (cold rolled) or 2.5 mm (hot rolled) smoothly finished,
leveled and free from flaws. Stiffeners should be provided
wherever necessary.
ii)
Panels should be indoor / outdoor type as specified in

specifications.
iii)
All outdoor panels and panels located in damp atmosphere should
have degree of protection not less than IP-55 as per IS:2147. All
indoor panels should have degree of protection not less than IP
52 as per IS:2147.
2.10.3
iv)
The panels should be suitable for cable / conduit entry form the top
and bottom. Suitable removable cable gland-plates should be
provided on the top and bottom of panels. Necessary number of
double compression cable glands should be supplied, fitted on to
these gland plates. The glands should be screwed on top and made
of tinned brass.
v)
Each panel should have a caution notice fixed on it.
vi)
Each panel should be provided with a circuit directory plate (of

anodised aluminium with the inscriptions indelibly etched on the
plate), which is fitted on the inside of the door.
vii)
Each lighting panel should be provided with one no. ON

indicating lamp for each phase along with fuses.
Main Bus Bars

Bus bars should be of aluminium alloy conforming to IS:5082 and should
have adequate cross-section to carry the rated continuous current and
withstand short circuit currents. Maximum operating temperature of the
bus bars should not exceed 85 deg. C. The bus bars should be able to
withstand a fault level of 20KA for AC panels and 16 kA for DC fault
level of 20KA for AC panels 16 kA for DC panels.
2.10.4
Switch-fuse units
Switches should be hand operated, air break, heavy duty, quick make,
quick break type conforming to IS:4064.
The rating of switches should be so chosen as to get complete protection
under all normal / abnormal conditions such as full load, overload, short
circuit etc.
2.10.5
Miniature Circuit Breakers (MCB)

The Miniature Circuit Breakers should be suitable for manual closing,
opening automatic, tripping under overload and short circuit. The MCBs
should also be trip free.
2.10.6
Contactors
Contactors should be of the full voltage, direct-on-line, air break, single
throw, electro-magnetic type. They should bd provided with atleast 2-NC
and 2 NO auxiliary contacts. Contactors should be provided with three
elements, positive acting, ambient temperature compensated time lagged
and reset type thermal overload relay with adjustable settings to suit the
rated current. Hand reset button provided on the fron of the cabinet should
be suitable for resetting with starter compartment door closed. The
Contactors should be suitable for switching on Tungsten filament lamp
also.
2.10.7
Push Buttons
All push buttons should be of push to actuate type having 2 NO and 2
NC self reset contacts. They should be provided with integral escutcheon
plates engraved with their functions.
2.10.8
Terminals
Stud type of terminals of ESSEN / ELMEX / TOSHA make or Equivalent
as should be specified. Terminals for outgoing and incoming should be
suitable for accepting the cable of specified size and numbers.
2.10.9
2.10.10
Labels
i)
The lighting panels should be provided on the front with panel

designation labels on a 3 mm thick plastic plate of approved type.
The letters should be black engraved on white back ground.
ii)
All incoming and outgoing circuits should be provided with labels.

Labels should be made of non-rusting metal or ply lamicold.
Labels should have white letters on black or dark blue background.
iii)
Lighting poles should be complete with fixing brackets and

junction boxes. Junction boxes should be mounted I m above the
ground level.
iv)
The lighting poles should be coated with bituminous preservating

paint on the inside as well as on the embedded outside surface.
Exposed outside surface should be coated with two coats of metal
primer (comprising of red oxide and zinc chromate in a synthetic
medium).
v)
The galvanised sheet steel junction box for the street lighting poles
should be completely weather proof conforming to IP-55 and
provided with a lockable door and HRC fuse mounted on a fuse
carrier and fuse bas assembly. The fuses should be as specified in
the relevant technical specifications. However, terminals should be
stud type and suitable for 2 nos. 16 sq. mm. cables. Necessary
arrangement for glanding cable along with supply of double
compression glands are included in vendors scope.
vi)
Distance of centre of pole from street edge should be

approximately 1000 to 1200 mm.
Ceiling fans and regulators

i)
The sweep ceiling fans should be complete with electronic

regulator and switch, suspension rod, canopy and accessories.
ii)
Winding of the fans and regulators should be insulated with class

E insulating material. Winding should be of copper wire.
2.10.11
2.11
iii)
Electronic regulator with smooth control be provided.
iv)
After installation it shall be ensured that fans and regulators

maintain reasonable degree of silence at all speeds.
v)
Fans and electronic regulators should be of reputed make.
Lighting wires
i)
The wiring used for lighting should be standard product of reputed

manufacturer.
ii)
The wires should be of 1100V grade, PVC insulated product of

reputed manufacturer.
iii)
The conductor sizes for wires used for point wiring beyond lighting
panels should be single core 4 sq. mm, 6 sq. mm, and 10 sq. mm
standard aluminimum wires and 2.5 sq. mm, 4 sq. mm, 6 sq. mm,
and 15 sq. mm, stranded copper wire.
iv)
The wires used for connection of a lighting fixture form a nearest

junction box or for loop-in loop-out connection between two
fluorescent fixtures should be single core copper stranded
conductor, 1100V grade flexible PVC insulated cords, unsheathed,
conforming to IS:694 with nominal conductor cross sectional area
of 2.5 sq. mm.
v)
The wires should be colour coded as followings:

Red for R
Phase
Yellow for Y
Phase
Blue for B
Phase
Black for
Neutral
White for DC
(Positive)
Grey for DC
(Negative)
Painting for shop made items

All sheet steel work should be phosphated in accordance with the
procedure in IS:6005 Code of Practice for Phosphating Iron and Steel.
Finished painted appearance or equipment should present an aesthetically
pleasing appearance, free from dents and uneven surfaces.
2.12
Test and test reports

i)
Type tests, acceptance tests and routing tests for the lighting
fixtures and accessories, covered in the specifications should be
carried out as per the relevant standards for the respective fixtures
and their accessories.
ii)
Manufacturers type and routine test certificates should be

procured for the fixtures and accessories.
iii)
Type tests, acceptance tests and routine tests for lighting panels
should be carried out as per relevant Indian Standard IS:8623. The
routine tests should also include tests specified under Technical
Specifications.
2.13
Important instructions
i)
All lighting fixtures should be complete with fluorescent tubes /

incandescent lamps mercury vapour / sodium vapour lamps and
these should be suitably wired up.
(ii)
All mercury vapour and sodium vapour lamp fixtures should be

complete with accessories like ballasts, ignitors, power factor
improvement capacitors etc. These should be mounted as far as
possible in the fitting assemble only. If these cannot be
accommodated inside, then a separate metal enclosed box should
be included to accommodate the accessories in addition with a fuse
and terminal block suitable for loop-in, loop-out connections.
Outdoor type fixtures should be provided with outdoor type
weatherproof box.
iii)
All fluorescent lamp fixture should be complete with all

accessories like ballasts, power factor improvement capacitors,
lamps, starters, holders etc.
High bay fixtures should be suitable for pendant mounting and the
flood lights should have suitable base plate / frame for mounting
on structural steel member. Hook mounted high bay fixtures are
not acceptable.
iv)
Each lighting fixture (other than bulk head fixtures) should have
terminal blocks suitable for 2.5 sq. mm. stranded flexible copper
conductor. The internal wiring should be completed and terminated
on the above terminal blocks.
Each lighting fixture should be provided with an earthing terminal suitable

for connection to 16 SWG GI earthing conductors.
v)
All metal or metal enclosed parts of the housing should be suitably

constructed so as to ensure satisfactory earthing continuity
throughout the fixture upto the earthing terminal.
vi)
The mounting facility and conduit knock-outs for the fixtures

should be as specified and should be suitable for 20 mm conduit
entry.
vii)
All surfaces of the fixtures should be thoroughly cleaned and

degreased. The fixtures should be free from scale, rust, sharp edges
and burrs.
viii)
All enamel finishing should have a minimum thickness of 2 mils

for outside surface and 1.5 mils for inside surface. The finish
should be non-porous and free from blemishes, blisters and fading.
ix)
The housing should e stove-enameled or vitreous enamelled or

anodized aluminium as indicated in the specification of the
relevant fixture.
x)
The surface should be scratch resistant and should show no sign of

cracking or flaking when bent through 90 deg. Over inch dia
mandrel.
xi)
All light reflecting surfaces should have optimum light reflecting

co-efficient such as to ensure the overall light output as specified.
xii)
The diffusing louvers used in the fluorescent fixtures should be

made of high impact Polysterene sheet and should have no
yellowing property over prolonged use.
xiii)
For certain areas the fixtures offered should be suitable for

provision dampers, if required during installation to enable the
lamps to performa the full lamp life.
xiv)
During raking over the healthiness of all the lamps should be

checked carefully.
xv)
All the manuals and booklets should be recorded, form the

suppliers during taking over.
CHECK FORMAT
1.
Materials received checked for their quantity, quality, YES/NO

correctness and identification marks as per the delivery challan /
MICC etc.
2.
All the materials, equipments, instruments inspected jointly YES/NO

with supplier and erection agency.
3.
All materials stored properly in such a way that retrieving of YES/NO

required materials is easy.
4.
Material record in the proper stock registers and duly signed by YES/NO
the concerned personnel.
5.
Working drgs. Are final, updated & apprd. With reference to YES/NO
actual site.
6.
Apprd. Drgs. Of particular areas available.
7.
If proper care taken to prevent the entry of water / moisture YES/NO

inside the items if stored outdoor.
8.
In case of spares, checks made for
YES/NO
i)
Physical damage
YES/NO
ii)
For their operation
YES/NO
iii)
Genuineness of spares especially filters, gaskets etc.
YES/NO
CABLES
9.
Lengths, types, size of cables are as per delivery challans / YES/NO

Labelling on drums.
10.
Cables ends properly sealed & IR values checked.
YES/NO
11.
Drums labeled for easy identification.
YES/NO
12.
Drums labelled for easy identification.
YES/NO
13.
Drums stored on slightly raised platform.
YES/NO
14.
Drums stored sufficiently away from water logging areas.
YES/NO
15.
Cable route is measured, cable (cutting) schedule is prepared & YES/NO

approved.
16.
Cable route is inspected to ensure route is clear.
YES/NO
17.
Cables are dressed and arranged properly on trays to avoid YES/NO

criss-crossing.
18.
Cable covered with sand in layers and by protective bricks.
YES/NO
19.
Cable trenches refilled with soil and rammed properly.
YES/NO
20.
Position of Cable markers checked.
YES/NO
21.
Cable identification tags provided at the ends of the cables as YES/NO

per Cable schedule.
22.
Cable entry in the Panels arranged as per wiring Diagram.
YES/NO
23.
Glanding, Lugs, Terminations, earthing provided.
YES/NO
24.
Tightening of Terminals checked.
YES/NO
25.
Cables are clamped at suitable intervals.
YES/NO
26.
IR values checked after cable laying.
YES/NO
27.
Following have been checked for Lighting Panels.
YES/NO
28.
Completeness of assembly of panels.
YES/NO
29.
Components layout and mounting.
YES/NO
30.
Wiring and connections
YES/NO
31.
Hardwares.
YES/NO
32.
Readiness of foundations for placement of panels.
YES/NO
33.
Leveling / grouting of anchor bolts & fasteners etc.
YES/NO
34.
Alignment
YES/NO
35.
Panels secured firmly to the mounting brackets.
YES/NO
36.
Tightness of hardwares & gasketting.
YES/NO
37.
Earthing of panels at two points.
YES/NO
38.
Functional checks of all components.
YES/NO
39.
Proper double compression glands and lugs terminated in YES/NO

panel / sub-lighting panels.
40.
All doors, removable covers and covers and plates gasketed all YES/NO
around with neoprene gaskets of specified material.
41.
Each lighting panel provided with one ON indicating lamp for YES/NO
each phase alongwith fuses.
42.
Panels mounted away form the windows and doors.
YES/NO
43.
Sufficient working space provided in a panel.
YES/NO
44.
Panels mounted as per the drawings.
YES/NO
45.
Necessary foundations / supporting structures for all outdoor YES/NO

type lighting panels and indoor lighting panels and indoor
lighting panels provided.
46.
During inspection of the panels, the meters, relays, switches YES/NO

mounted on the panel are found intact.
47.
In each panel the distribution circuit drawing has been pasted.
48.
Panels are suitable for cable / conduit entry from the top and YES/NO
bottom.
49.
Each panel has a caution notice fixed on it.
50.
If each panel provided with a circuit directory plate which is YES/NO

fitted inside of the door.
51.
Terminals for outgoing and incoming cables are suitable for YES/NO
accepting the cable of specified size and numbers.
52.
Lighting panels are provided on the front with panel designation YES/NO
labels on a 3 mm thick plastic plate of approved type.
YES/NO
YES/NO
53.
Letters on the labels are black engraved on white back ground.
YES/NO
Conduits / Pipes
54.
Conduit routes planned in such a way to achieve minimum YES/NO

crossings.
55.
Conduits routes selected in such a way so that conduit lengths YES/NO

are optimised.
56.
All the surface conduits are running under the ceiling and in the YES/NO
wall just below the ceiling.
57.
Conduits are running straight.
YES/NO
58.
Conduits are running on a levelled surface.
YES/NO
59.
Conduits are fixed on saddles.
YES/NO
60.
All wires in a conduit are drawn simultaneously.
YES/NO
61.
Pulling of wires through more than two equivalent 90 deg. YES/NO

Bends in a single conduit run is avoided.
62.
AC and DC wiring are not running through the same conduit YES/NO
boxes, for easy maintenance and without taking din the fixture.
63.
Conduits / Piles laid as per marking done / conduit layout / YES/NO

route draing.
64.
Size of Conduits / Pipes selected on the basis of No. of wires to YES/NO

be drawn.
65.
Conduits / Pipes secured to the Spacers / Supports at a YES/NO

maximum interval of 750 mm for horizontal runs and 1000 mm
for vertical runs.
For embedded system
66.
i)
Minimum 38 mm spacing between adjacent conduits /

YES/NO
pipes is provided.
ii)
38 mm Depth of conduit from the finished surface is YES/NO

maintained.
iii)
G.I. Wire (Fishwire) provided for pulling wires.
YES/NO
66.
For embedded system

iv)
Minimum 38 mm spacing between adjacent conduits /

YES/NO
pipes is provided.
v)
38 mm Depth of conduit from the finished surface is YES/NO

maintained.
vi)
G.I. Wire (Fishwire) provided for pulling wires.
YES/NO
67.
Bending radius of the conduit pipe atleast four times of the dia YES/NO
of the
68.
Conduits / pipe joints and connections made water tight and rust YES/NO
proof by applying white lead for embedded conduit and Red
Lead for exposed conduit.
69.
Conduit / Pipe end plugged after installation to prevent entry of YES/NO

any foreign material.
All exposed conduit / pipes laid parallel to the building / area YES/NO
line / column / beam etc.
70.
71.
Conduit / pipes not in direct contact with water / soil.
72.
Each pieced of conduit is straight, free from blisters and other YES/NO
defects.
Conduits pieces furnished in standard lengths as per YES/NO
specifications and threaded at both ends.
73.
YES/NO
Receptacles
74.
75.
Receptacles provided near those equipments where electric YES/NO

supply may be required.
Receptacles fixed at the places as mentioned in the drawings.
YES/NO
76.
In the outdoor area the location of receptacles chosen carefully YES/NO

based on the power supply requirements at that point (like
welding transformers, blowers etc.).
77.
Receptacles equally spared through out the switchyard area.
YES/NO
78.
Erection of Receptacles
Correct selection of type of Receptacles as per Drawing.
YES/NO
79.
Necessary holes made for conduit entry.
YES/NO
80.
Holes are Dust / Vermin proof.
YES/NO
81.
Receptacle Boxes secured firmly on the mounting bracket / wall YES/NO

/ column / steel structure Tightness of Hardwares.
82.
Alignment of Receptacle Boxes checked.

Correct connection / looping and colour cooling of wires.
83.
YES/NO
YES/NO
84.
Earthline is connected to third pin.
YES/NO
85.
86.
Wires connected properly as per Wiring / Connection Diagram YES/NO

(Incoming / Outgoing).
Wires of each circuit checked out for continuity, if necessary.
YES/NO
87.
Tightness of Connections checked.
YES/NO
88.
YES/NO
89.
Earthing Connection and continuity checked.

Tightness of Connections checked
90.
Earthing Connections checked
YES/NO
91.
Incoming and Outgoing circuits directory affixed to the panels.
YES/NO
92.
Functional Check of all components performed.
YES/NO
93.
IR Value taken.
YES/NO
94.
Check / indicating lamps of voltage / current meters.
YES/NO
95.
Fixtures secured firmly on the mounting brackets / Tightness of YES/NO

hardwares etc.
YES/NO
Flood Lights
96.
Flood Lights installed on lightning masts / switchyard structures YES/NO

wherever required at site.
97.
Fixtures mounted on Galvanised Mast making use of shop YES/NO

provided holes or by suitable clamps.
Street Lighting Poles
98.
Street lighting poles installed as per the approved drawings YES/NO

during detailed engineering.
99.
Excavation performed upto the required depth.
100.
Level and the line f lighting poles checked and kept same for all YES/NO
the poles.
101.
After final finishing and coping the site is cleared.
102.
Lighting poles are complete with fixing brackets and junction YES/NO
boxes.
103.
All lighting poles are earthed as per approved drawings and YES/NO
specifications.
Poles are checked for
YES/NO
YES/NO
i)
Dimensional Conformity
YES/NO
ii)
Weight of Poles
YES/NO
iii)
Straightness of Poles
YES/NO
iv)
Pole Cap / Base plate provided.
YES/NO
v)
Bituminous Paint on inside surface and Red lead oxide YES/NO

primer coat on outside surface provided.
vi)
Poles Section dimensions.
vii)
Marking of the portion which will be embedded in the YES/NO

earth.
viii)
ix)
Verticality of the poles and alignment with reference to YES/NO

other poles.
YES/NO
Correctness of Concrete mixture of pole foundation.
x)
Two coatings of Aluminum Paint after erection.
xi)
Earth electrode connected to pole by means of earth YES/NO

strip.
xii)
Earthing Resistance value of poles.
YES/NO
YES/NO
YES/NO
Emergency Lights
104.
Emergency portable Lighting Fixtures provided in control room YES/NO

and those places where illumination is required in case of
emergency / total failure.
105.
Portable fixtures checked to come up automatically in the event YES/NO

of failure of normal supply.
106.
Junction boxes are weather proof type with gaskets confirming YES/NO
to specifications.
107.
Junction boxes mounted 1m above the ground level.
108.
Galvanised sheet steel junction boxes for street lighting poles YES/NO
are completely weather proof and provided with a lockable
door.
109.
Wiring spliced only at junction boxes with approved type YES/NO

terminal strip.
110.
For lighting fixtures, connection teed off through suitable round YES/NO
conduits or junction.
Lighting transformers
YES/NO
111.
Transformers are stored either inside or in the open, sufficiently YES/NO

covered.
112.
Lighting transformers have been tested for

YES/NO
(i)
Ratio test (at each tap)
(ii)
(iii)
Terminal tightness
vii)
Phase control
viii)
Current in each phase
ix)
x)
Terminal tightness
xi)
Foundation
xii)
Placement requirements w.r.t. incoming and outgoing YES/NO

cables.
xiii)
Cubicle earthing at two points and effective dust sealing. YES/NO
(xi)
IR value of transformer.
xiv)
Earthing of neutral done.
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
Lighting Fixtures
113.
Each lighting fixtures provided with an earthing terminal YES/NO

suitable for connection to 16 SWG GI earthing conductors.
114.
All surfaces of fixtures are thoroughly cleaned and degreased.
YES/NO
115.
Fixtures are free from scale, rust, sharp edges and burrs.
YES/NO
116.
During taking over healthiness of all the lamps checked YES/NO

carefully.
Switch Boxes
117.
Completeness of assembly of Switch Boxes Checked.
YES/NO
118.
Wiring & Connections Facilities provided as per specfn.
YES/NO
119.
Adequate knockouts for conduit entry provided on Switch YES/NO

Boxes.
Erection of Switch Boxes
120.
Correct Selection of Switch Boxes as per Drawings for YES/NO

controlling specified NO. of circuits.
121.
Location & mounting checked.
YES/NO
122.
Necessary holes made for conduit entry.
YES/NO
123.
Holes are Dust / Vermin proof.
YES/NO
124.
Alignment of Switch Boxes checked.
YES/NO
125.
Switch boxes secured firmly on the mounting bracket / YES/NO

Tightness of Hardwares etc.
126.
Correct connection and colour coding of wires checked.
127.
Wires connected properly as per Wiring / Connection Diagram YES/NO

(incoming / Outgoing).
128.
Identification of wires of each circuit b checking continuity.
YES/NO
129.
YES/NO
130.
Earthing connections checked
YES/NO
131.
IR Values taken
YES/NO
YES/NO
Lighting wires
132.
Coils stacked in order of size / colour properly labeled and YES/NO

tagged for easy identification.
133.
All wires pulled smoothly and simultaneously through conduits. YES/NO
134.
Insulation of wires not damaged during pulling.
135.
Wires spliced with proper splicer and connected properly to the YES/NO
Switches / Fixtures / Panel / Sw. Boxes as per Wiring Diagram.
136.
Correct Connections and Correct Colour coding for each Circuit YES/NO
done.
137.
YES/NO
138.
Proper lugs & Identification ferrules provided.
YES/NO
139.
The wires are colour coded as follows:
YES/NO
Red for R Phase
YES/NO
Yellow for Y Phase
YES/NO
Blue for B - phase
YES/NO
140.
Wiring done as per the circuits given in the approved drawings.
YES/NO
141.
After completion of wring works, site cleared for other works.
YES/NO
142.
Wires properly and neatly dressed
YES/NO
143.
Not more than 2 wires terminated to each side of the terminal YES/NO
block.
144.
Wires connected properly as per Wiring / Connection Diagram.
YES/NO
Junction Boxes
145.
Check if adequate knockouts have been provided on the JB.
YES/NO
146.
Necessary holes are made for conduit entry.
YES/NO
147.
Holes drilled are made dust / vermin proof.
YES/NO
148.
Alignment of JBS is perfect as per drawing.
YES/NO
149.
All the wiring connections are done as per drawings.
YES/NO
Emergency Light Unit

150.
Type / rating and Qty. of ELU as per packing list / Delivery YES/NO
Challan,
151.
Battery stored separately on raised ground.
YES/NO
152.
All electrical connections checked.
YES/NO
153.
Specified gravity of acid is filled in battery and battery put on YES/NO

charge.
154.
Supply plug, socket & unit are functionally operative.
YES/NO
General
155.
Equipments installed in a neat, workman-ship manner.
YES/NO
156.
Erected equipments checked so that these are in level, plumb YES/NO

square, properly aligned and oriented.
157.
Tolerances established as per the apprd. Manufacturers drgs. YES/NO

Or as stipulated in the technical specifications.
158.
Necessary care exercised in handling to avoid the distortion of YES/NO

structures, the marring of finish or damaging of delicate
instruments or other electrical parts.
159.
All lighting panels, junction boxes, fixtures, conduits etc. are YES/NO
grounded in compliance with the provisions of I.E. Rules.
160.
Lux levels in all the areas checked.
YES/NO
161.
Healthiness of all the lamps checked.
YES/NO
162.
All welds, bolt holes, conduit entry holes etc. made during YES/NO
installation brushed with wire and touched up with metal
primer.
163.
Sweep ceiling fans are complete with electronic regulator and YES/NO
switch, suspension rod, canopy and accessories.
164.
Minimum lux levels maintained in the different areas both YES/NO

indoor and outdoor.
165.
All the manuals and booklets received form the suppliers during YES/NO
taking over.
________________________________________________________________
CHAPTER
THREE
________________________________________________________________
AUXILIARY POWER SUPPLY

3.0
33 KV-11 KV / 415 V Substation

Two sources of HT supply have to be requisitioned from local SEB
authorities to meet station auxiliary loads reliably. Local SEB extends HT
supply 33 KV or 11 KV. Necessary LT substation to step down to 3 phase
415 V has to be constructed and commissioned. So the estimation,
tendering, award and execution of the work and release of supply form the
State Electricity Board is to be well planned and coordinated to suit our
requirements. Application to be forwarded immediately after the general
layout of the 400 KV substation showing the location of 33-11 KV / 415
Volts substation is approved.
3.1
Equipments in 11 / 33 KV / 415 substation:

The following are the major equipments:
i)
LT TRANSFORMERS 33 11 KV / 415 VOLTS 630 KVA.
ii)
Circuit Breakers
iii)
Isolators
iv)
Lighting Arrestors
v)
Current Transformers
vi)
Potential Transformers
vii)
Transformer control and Relay panels
The capacity of the transformer is generally decided by the starting current

required for our motors in fire fighting system. Considering the present
requirements in our substations, transformers for capacity of 630 KVA is
being used.
3.2
Classification of Activities

The main activities, involved in a typical ---------- LT supply contract are
3.3
i)
Material receipt at site.
ii)
Inspection of Materials.
iii)
Storage of Material.
iv)
Erection of equipments / systems
v)
Testing & Commissioning.
Receipt of Materials
The procurement of Transformers only is being arranged by our Corporate
Centre. All other equipments are procured by the Regional office. The LT
transformers are supplied by the manufacturing agency. The erection
supervision also will be carried out by the manufacturer. However, receipt,
storage and erection of the transformer on the plinth is generally in the scope
of LT substation package.
3.4
Inspection of Materials
All the materials are to be jointly inspected with supplier and erection
agency. This inspection is required to check the materials received for its
quantity, quality, correctness and identification marks as per the delivery
challan / packing list etc.
3.5
Storage
The erection agency is allowed to stored properly in such a way that
retrieving of required materials is easy. Maintenance of proper stock register
by the erection agency is to be checked at least once in a week by duly
counter signing the equipment is to be stored indoor wherever possible
otherwise they have to be covered with water proof tarpaulins. The
unloading can be slowly pushed into the building and positioned by using
required nos. of MS / GI pipes.
3.6
Substation Layout
The layout of 33 / KV substation is prepared at Regional / Divisional level

only. Provision is to be made in the layout for erection of the metering
equipment (HG fuse Set, CT, PT, LA and the energy meter) by local
Electricity Board.
3.7
Supply and erection of Equipments

LT substation package includes Supply, Erection, Testing of the 33-11KV /
415 V substation equipments, structures etc. A typical specification list is
enclosed in the guidelines. The BOQ should also include the spares for
circuit breakers, one spare for each type of CT, PT, Isolator, LA and one set
of terminal connectors. It will also include the earthing arrangement for the
substation i.e., earth pits for earthing of all equipments and structures.
3.8
Commissioning tests
All precommissioning tests for transformer, circuit breakers, PTs and
isolators are to be carried out. The energy meter is to be jointly calibrated.
The test formats are given below.
3.9 Precommissioning test formats for LT substation: requirements

for testing and commissioning
I)
Checks
a)
Field Quality Plan
b)
Factory test report of the equipments
c)
Erection key diagram
d)
Schematic diagram
e)
Megger 500 V 1000 M. Ohms, 10 K.V. 100000 M. Ohms
f)
Digital multimeter
g)
Tan Delta & Capacitance Measuring Bridge
h)
Heating arrangement with standard thermometer
ii)
(iii)
(iv)
(v)
i)
Motor Checker
j)
Kelvin Resistance Bridge with Battery
Breakers
a)
Insulation resistance of each pole.
b)
Check adjustments, if any, suggested by manufacturer.
c)
Breaker closing and tripping time.
d)
Slow and power closing operation and opening.
e)
Trip free and anti pumping operation.
f)
Minimum pick up volts of coils.
g)
Contact resistance.
h)
Insulation resistance control circuit.
i)
Resistance of closing and tripping coils.
Isolators
a)
b)
Manual operation.
c)
Ground connections.
d)
Contact resistance.
e)
Proper alignment so as to minimise the vibrations during

operation to the extreme possible.
Current Transformers
a)
Insulation resistance tests.
b)
Polarity test.
c)
Ratio identification test-checking of all ratios on all cores

by primary injection of current.
d)
Magnetisation Characteristics test.
Voltage Transformers
(vi)
(vii)
a)
Insulation resistance test.
b)
Polarity test.
c)
Ratio test.
d)
Dielectric test of oil (wherever applicable).
Lightning Arrestors
a)
Leakage current.
b)
Resistance of ground connection.
Phasing out
The phasing out of all supplies in the station system is to be carried
out.
(viii)
Station Earthing
a)
Check soil resistively.
b)
Check continuity of grid wires.
c)
Check earth resistance of entire grid as well as various

sections of the same.
d)
Check for weld joints and application of zinc rich paint on

galvanised surfaces.
(ix)
ACSR Stringing work, tubular bus work and power
connections.
(x)
a)
Physical check for finish.
b)
Electrical clearance check.
c)
Testing of torque by torque wrenches on all bus bar power

connections and other accessories.
d)
Milli-volt drop test on all power connections.
e)
Sag and tension check on conductors.
Insulators
Visual examination for finish, damage, creepage distance
etc.
(xi)
Transformers
TEST FORMAT
SUBSTATION
: 33 / .415KV
: TEST DATE
EQUIPMENT
: 11/.415 KV
: TRANSFORMER
: ENERGISATION
: DATE
Details of equipment:
MAKE
SL. NO.
KVA RATING
VOLTAGE
CURRENT
VECTOR GROUP
NO OF TAPS
: __________ IN STEPS OF _________.
% OF IMP.
: __________ %
APPLICABLE STD.
: IS 2026
TYPE OF
: HV OPEN BUSHING
CONNECTION
: LV
3.10Precommissioning test results of Transformer

(i)
IR. Values.
DEATAILS OF INSTRUMENT USED:
------------------------------------------------MAKE
SL. NO.
RANGE
RESOLUTION
HV - E
(ii)
iii)
(iv)
LV E
HV - LV
DC Winding resistance (in ohms):

R
Oil test results:

BDV
TAN DELTA
SP. RESISTANCE
MOISTURE CONTENTS
ACIDITY
Magnetising current:
APPLIED VOLTAGE =
MEASURED CURRENT =
(v)
Short Circuit Test:

LV SHORTED, WITH LOW VOLTAGE APPLIED ON HV
SIDE.
SL. VOLT S.C. CURRENT CALCULATED VALUE AS PER

NO. APPL. MEASURED ON PER % OF IMPEDANCE ON HV
LV SIDE
SIDE R (amp) Y (amp) B (amp)
vi)
SL. NO.
vii)
Magnetic Balance:
VOLTS APPLIED
ON PRIMARY
RY YB BR
HV. SIDE
LV. SIDE
Relay settings.
SL. NO.
x)
REMARKS
Protection provided:
SL. NO.
viii)
INDUCED VOLTS
IN SECONDARY
rn yn bn ry yb br
RELAY TYPE
SETTINGS
RECOMMENDED
SETTING
ADOPTED
Earth resistance value:

INDIVIDUAL PITS
COMBINED RESISTANCE
1.
Ohms
2.
Ohms
Ohms
xi)
SL.
NO.
Check and calibrate WTI / OTI

with hot oil bath and std. Thermometer
TEMP.
STD.
OF
TH.
1.
50OC
2.
60OC
3.
70OC
4.
80OC
5.
90OC
6.
100OC
WTI
OTI
%ERROR
CLEARED FOR ENERGISATION

TEST REPORT REVIEWED AND ACCEPTED
SIGNATURE
SIGNATURE
NAME
NAME
DATE
DATE
3.11Inspection by
equipment:
Central
Electricity
Authority
to
energise
the

All the erected equipments in the 33 / 11 KV substation are also to be got
inspected by the Inspectorial wing of Central electrical Authority and
permission is to be obtained for energisation. Format for Application for this
purpose is enclosed as Annexure I.
3.12
Release of supply by the State electricity Board

After payment of all the requisite fee and charges, the State electricity Board
will take up the laying of the service line, erect the metering equipment in
our substation premises. As the procurement of equipments, laying of the 33
/ 11 kv line are time consuming process for the State Electricity Board side
is to be monitored to suit our programme of commissioning. Unless the 33 /
11 KV substation is commissioned, the trail runs of fire protection system
and air conditioning systems can not be carried out, as the capacity of
construction power is not sufficient. For commissioning of 33 11KV / 415
Volts substation, 220 Volts Battery of the station is also to be made
available.
3.13
Technical Specifications
For all the equipments being supplied, the detailed drawings showing the
parameters, specifications etc. are to be submitted for approval of
POWERGRID. Routine and type test certificates for all the equipments are
also to be furnished for approval.
(i)
Transformer:
Description
Parameters
(i)
Type
Two winding
(ii)
Service
Outdoor
(iii)
No. of Phases
Three
(iv)
Frequency
50 Hz
(v)
Type of cooling
ONAN
(vi)
Rating
630 KVA
Rating
33 / 0.415 kV
(vii)
Impedance at 75OC with tolerance
0.05 + 10 %
(viii)
Duty
Continuous
Overload
As per IS:6600
Sl. No.
(iii)
(ix)
(x)
(xi)
Maximum Temp. rise

ambient temperature.
over
50O
(a)
Of top Oil (Temp. rise

measurement by
thermometer)
50OC
(b)
Of Windings (Temp. rise

measured by resistance
resistance method)
55OC
Windings
33 kV
415 V
a)
b)
c)
d)
e)
___
Delta / Star
Dynl
Uniform
33 kV
___
415 V
System fault level

Winding connection
Vector Group
Insulation
Insulation level
(xii)
Power frequency test level (KV rms)
70
(xiii)
Basic impulse level. (KV peak)
170
__
(xii)
(xiv)
Highest voltage
winding
(KV)
for
each 36
(xii)
(xv)
Method of earthing
Solidly earthed
(xii)
(xvi)
(xii)
Tap Changer
a)
Tap range
b)
Tap control
+ 5% in steps of 2.5%
on HV side
Off circuit tap change
switch
(xvii)
H.V. Bushings
(xii)
a)
Rated voltage
36 kV
b)
Rated current
100 A
c)
Basic impulse Level (KV)
250
d)
Wet and dry power frequency 75

withstand voltage (KV rms)
e)
Total Creepage distance (mm)
f )
Mouting
900
Tank / Transformer
body
L.V. and Neutral bushing

(xv)
(xii)
(xii)
a)
Rated Voltage (Volts).
1100
b)
Rated current (amps)
1100
Terminal details
(k)
High Voltage
Suitable for 33 overbead
(l)
Low Voltage phase and

Neutral
Minimum Clearance (mm) in
Air
Phase to Phase
Phase to Earth
Conductor or cable
m)
n)
o)
(ii)
33 KV
415 V
350
320
25
25
Fittings
The following fittings should be provided with the transformer.
(i)
Conservator with drain plug and oil filling hole with

blanking plate
(ii)
Plain Oil Gauge
(iii)
Silica Gel Breather
(iv)
Pressure Relief vent
(v)
Pocket on tank cover for Thermometer
(vi)
Valves
(vii)
Earthing Terminals
(viii) Rating & Terminal Marking Plates

(ix)
Lifting Lugs
(x)
Rollers
(xi)
Air release Plug

The fittings listed above are only indicative and any other
fittings which are generally required for satisfactory
operation of transformer are deemed to be included.
(iii)
Other Equipmets
(a)
33 KV Post Insulators
(b)
3 phase gang operated

Centre mounted double
break. Manual operated
and
without
any
mechanism for remote and
local operation.
Vacuum Circuit Breaker
33 KV VCB, 1500 MVA
rupture, capacity with local
and remote operation.
(c)
(a)
(d)
33KV Current Tr.
It should have 2 Nos. of

33KV Post Insulators per
stock.
Specified CT Ratio, Outdoor

oil
filled,
Vacuum
impregnated.
Core I rating : Specified VA
& duty core II rating :
Specified VA & duty Core III
rating : Specified VA & duty
short time current : As per
specn. Insulation Level : As
per specn.
(e)
33KV P.Ts.
(b)
(f)
Station class 33KV LA
(a)
(g)
Control Panel
(f)
(a)
Out door, oil filed, or dry cast

resin vacuum impregnated.
Voltage Rating : 33/; /
110/3, 100 VA Class &
Accuracy : As per specn.
Insulation level 70/170kV,
50Hz, 33kV as per IS 3166.
33KV gapless LA
Simplex, indoor, sheet steel,

cubic type, floor mounted,
internal
wiring
fuses,
terminal board, heater with
switch, plug and socket
illumination lamp, earth bus.
Dimension : As per specn.
Painting : As per specn.
Panels consist of:
1)
ODS Breaker control
Switch
2)
ODL Lamps
3)
ODS-Local / remote
selection switch
4)
(a) Ammeter : Qty.
& type as per
specn.
(b) Voltmeter : Qty.
&type as per
specn.
5)
Position selection
Switches
(6)
DC Bell
(7)
KWH meter 3 wire, 2

element switches :
Qty. As per specn.
(8)
IDMT O/C, E/F relay
(9)
Aux. As relay
Oty. : As per specn.
(f)
(a)
(f)
(a)
(f)
(a)
(f)
(a)
(10) Alarm relay

Qty. : As per specn.
(f)
(a)
NOTE: The control panels are to be erected in the control room building.
The erection of panels includes fabrication and supply of base frames of
suitable size if necessary.
(iv)
Cabling
Cables to be laid form the control panels to various equipments
like CBs, Transformers, CTs and PTs are to be supplied by
POWERGRID. All the other accessories like cable glands, lugs,
ferrules etc. are to be procured by the contractor. The cables are to
be laid in the ground in buried cable trench and / or in the
switchyard cable trenches. The cables should be neatly tied and
clamped with brackets etc.
(v)
Earthing:
All the equipments structure and filling posts are to be connected
to the earthmat.
(vi)
Metal spreading
Before spreading of the metal, the substation is to be levelled to the
required level, watered and rolled with light roller to get smooth
finished surface.
(vii)
Spare parts:
The list of spares for outdoor type transformers in a typical LOA is
given below:
a)
Bushings with metal parts one
(1)
No.
each type
3.14
b)
Oil temperature indicator one
(1`)
No.
c)
Diaphragm for pressure relief vent One
(1)
Set
d)
Tap changer contacts
(1)
Set
e)
Set of valves One
(1)
No.
Performance Guarantee:
The equipments supplied and erected should be guaranteed for satisfactory

performance for a period of 12 months form the date of commissioning of
the Substation. Any defective equipment should e repaired / replaced free of
cost irrespective of the guarantees furnished by the vendors.
The substation including all the equipments should be erected, tested and
commissioned. All the necessary per-commissioning tests as specified in the
FQP should be done.
GUIDELINES
3.15
Receipt and Joint Inspection

(i)
The equipment received at site will be generally handed over to the

erection contractors directly.
(ii)
Joint verification with the representative of the Supplier, Erection

Contractor and the representative of Corporation is to be done.
iv)
3.16
If the supplier does not send his representative to site in time

(Within one month) for joint verification, after due notice, we have
to take up the verification alongwith the erection contractors, and
intimate to the supplier the discrepancies, if any. This is essential
as the transit insurance of the equipment is valid generally 2
months of receipt of the materials at site.
Erection Supervision
(i)
All the eqipments i.e. CBs, CTs, CVTs Isolators etc. are
erected by the Switchyard erection contractor.
(ii)
The erection and commissioning is to be carried out under
the close supervision of the manufacturers representative. This is
particularly in the case of circuit breakers and Isolators. The Site
Manager has to co-ordinate to ensure that the representative of the
manufacturer is available at site at the time of erection.
3.17
Commissioning
(i)
After erection and carrying out pre-commissioning tests of the

respective equipment, the representative of manufacturer usually
clears the equipment for charging and leaves the site.
(ii)
The energisation of the equipment is done after completion
of erection of all the equipments in the substation and after the
concerned incoming line is made ready.
(iii) Hence, at the time of energisation of the equipment, it is
desirable that the representative of the manufacturer of each
equipment is available at the sub-station. This helps in repair /
rectification of the defects noticed at the last moment or noticed
during energisation.
v)
3.18
The site Manager has to co-ordinate with the Supplier /

Manufacturer in this regard.
Progress reports and review meetings

3.19
(i)
Progress reports (Fortnightly or Monthly) indicating the supply and

erection status of various equipments are to be insisted form the
erection contractors.
(ii)
Fortnightly review meetings are to be conducted at the substation

to review the progress and sort out co-ordination problems between
the erection agencies. In these meetings definite commitment is to
be obtained from the Contractors regarding Fortnightly / Monthly
targets.
Progress Payments
(i)
To carry out the work smoothly and to complete within the
schedule, the progressive payments for the portion of the
completed works, are to be effected very promptly.
(ii)
The measurements are to be taken, progressive bills
prepared and sent to Finance Department for passing and payment.
Flow of Funds is also to be ensured by sending case flow
particulars to Finance.
3.20
General
(i)
Isolators and the Circuit Breakers are the equipments in
which troubles may arise during the O&M stage. Hence, our
Engineers and Supervisors have to closely follow the erection
activities to enable them to acquire the erection techniques and the
rectification of the defects.
(ii)
The following are some of the items wherein it is likely that
the information to the full extent is not available or the information
is with mistakes / errors.
a)
Cable laying schedules
b)
Cable termination schedules
c)
Wiring drawings
(iii)
Source of HT supply in 33 / 11 / 400 V s / stn. Should preferably

be a dedicated source.
(iv)
As ti is always not possible to get a dedicated source of supply and

we may have to tap the feeder from a nearby source. In such a
condition 33 KV should be preferred over 11 KV feeder.
vi)
In case none of the above options is available and 11 KV feeder

choice is left then it should be possibility selected from an urban
feeder. This is because of better reliability and availability of the
urban feeder.
vii)
It should also be preferred that the 33 /11 KV HT incoming

feeder is emanating form a nearby 132 KV substation. This is done
to enhance the availability and reduce the interruptions in the
incoming supply.
viii)
For higher redundancy of the system, both the incoming feeders

should be tapped form two different substations of Electricity
Board. However in case if it becomes necessary to tap both the
sources from the same substation both should be tapped form two
different transformers.
ix)
The location and layout of the 33 / 11 KV substation should be

such that the incoming feeders can come straight to the equipments
avoiding extra length of feeder around the substation.
x)
Proper fencing should be provided in the LT transformer / yard

area and proper danger marks / plates should be provided so as to
restrict the entry of outside personnel / stray animals near the
charged equipments to avoid any mishappening.
xi)
While designing the Fire Fighting system in a substation a fire

hydrant connection should be provided near the LT substation to
meet any fire hazards.
xii) Proper gravel filling should be done in the LT switchyard area.

xiii) Even if second LT transformer is not in use for some time it should
be kept under charged condition so as to ensure its availability
during any eventuality.
xiv) If possible, a proper bus bar with bus sectionalising arrangement
should be provided on HT side, so that in case of outage of one
transformer and the other feeder atleast 50% availability from the
other feeder and transformer can be maintained.
xv) Prior to filling in main tank at site the transformers should be

tested for BDV and Moisture contents, Tan-delta, Resistivity and
Interfacial tension as per the technical specifications.
ANNEXURE I
H.T. REQUISITION APPLICATION FORM

(Typical for a 400 kV Substation)
A request application in the following FORMAT is sent to the concerned
SEBs office giving the desired details.
(i)
Name of the Consumer
(ii)
Address
(iii)
Status of Customer
(iv)
Location of Premises
where supply is required
:
:
(v)
Nature of supply
(vi)
Purpose of supply
(vii)
Details of connected load

and maximum load
Schedule of requirement
of power
(viii)
(ix)
Technical data
(a)
Contracted M.D.
(b)
Power Factor
(c)
Load Factor
(d)
No. of working hours
(e)
No. of working days
(f)
(g)
(h)
in a month
No. of working months

in a year
Total HP connected for

machinery
Total lighting power

required
x)
Our conformation that we should abide by terms and conditions of

supply notified by SEB from time to time.
xi)
Our conformation that we should pay the SEB inspection fees, cost
of service lines and other charges as demanded by the board.
xii)
Location map of the substation site should be enclosed along with

this application.
POWERGRID
SR. ENGR. / DY. MANAGER
DATE
ANNEXURE II
CENTRAL ELECTRICITY AUTHORITY
ELECTRICAL INSPECTORATE FOR VARIOUS UNION TERRITORIES /

CENTRAL GOVERNMENT INSTALLATIONS
FORM TO ACCOMPANY THE APPLICATION FOR APPROVAL OF THE

ELECTRICAL
INSPECTION
TO
ENERVISE
THE
H.V.
E.H.V.
APPARATUS / INSTALLATIONS ETC. UNDER RULE 63 OF THE INDIAN

ELECTRICITY RULES, 1956.
(i)
Date of application
(ii)
Probable date of completion :
(iii)
Target date of commissioning
(iv)
Name of apparatus / installation
(v)
Drawing showing the location of

apparatus installation to be
attached
Type of installation (such as

indoor, pole mounted, platform
mounted, step down, control etc
Capacity of the installation its

Name plate details to be
attached
(viii) Schematic diagram of the

installation along with reference
to the installation already
energised in the vicinity to be
attached
(vi)
(vii)
(ix)
(x)
Details of the control and

switchgears provided
Details of protection provided

such as
a)
b)
(xi)
(xii)
Short circuits
LT Line protection
Minimum clearance of the

elevant exposed live conductor
from the ground
Whether efficient earthing is

provided. The diagram of the
earthing electrodes and earthing
system to be attached
:
(xiii) Copy of results of H.V / EHV test

carried out for each apparatus to
be enclosed
(xiv)
(xv)
(xvi)
An attested copy of test result /

and / or manufacturers test
certificate to be enclosed for
each apparatus.
Whether all relevant provision of

the I.E. Rules 1956 have been
duly complied.
Whether the installation has

been examined and properly
checked
(xvii)
A copy of test result in respect to

the following to be furnished
(a)
Insulation resistance :
H.V. EARTH / LV EARTH / HV . L

(b)
250 KVA 11000 / 433 V Transformer
(c)
BDV of insulating Oil
CHECK FORMAT

1.
Materials received checked for their quantity, quality, YES/NO

correctness and identification marks as per the delivery challan /
packing list etc.
2.
Materials received at site have been checked for

(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Physical damage.
Visual examination of zinc coating / plating.
Name plates that all times are as per order /
specifications.
Tightness of all bolts, clamps and connecting terminals
using torque wrench.
For oil leakages, Oil level and top up wherever
necessary.
Ground connections
Cleanlines of insulators an bushings.
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
3.
All the materials, equipments, instruments inspected jointly with YES/NO

supplier and erection agency.
4.
All materials stored properly in such a way that retrieving of YES/NO

required materials is easy.
5.
Material record entered in the proper stock registers and duly YES/NO
signed by the concerned personnel.
6.
If store building is not ready, the equipments are stored indoor YES/NO
otherwise these have been covered with water proof tarpaulins &
stocked properly.
7.
Breakers
If the following have been checked.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
8.

Adjustments, if any, suggested by manufacturer.
Breaker closing and tripping time
Slow and power closing operation and opening.
Trip free and anti pumping operation.
Minimum pick up volts of coils.
Contact resistance.
Insulation resistance control circuit.
Resistance of closing and tripping coils.
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
Isolators
If the following have been checked.
9.
(i)
(ii)
(iii)
(iv)
(v)

Manual operation.
Ground connections.
Contact resistance.
Proper alignment so as to minimise the vibrations during
operation to the extreme possible.
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
(vi)
(vii)
Damage to porcelain.
YES/NO
YES/NO
Receipt of all components as per packing list.
CT / VT
If the following checks / tests have been carried out.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
(xiii)
(xiv)
10.
11.
12.
Packing cases for external damage & oil.

Oil level.
Name plate ratings.
Mechanical damages, cracks, deformations or deep
scratches.
Leakage of Nitrogen..
Terminal identification markings for CT & neutral for
CVT clearly marked.
Proper & careful handling of CT / VT ensured.
CT / VT have been stored vertically or as per
manufacturers recommendations.
Polarity test.
Ratio identification test-checking of all ratios on all cores
by primary injection of current.
Magnetisation Characteristics test.
Dielectric test of oil (wherever applicable).
Lightning Arrestors
IF the following checks / tests have been made.
(i)
Leakage current.
(ii)
Resistance of ground connection has been measured.
Damage to porcelain checked.
(iii)
Receipt of all components is as per packing list.
(iv)
Name plate rating checked.
(v)
External damage to the packings cases checked.
(vi)
Surge monitor mounted at the convenient height.
(vii)
Phasing out
The phasing out of all supplies in the station system has been
carried out.
Station Earthing
If the following have been checked / measured.
(i)
Soil resistivity.
(ii)
Continuity of grid wires.
(iii)
Earth resistance of entire grid as well as various sections
of the same.
(iv)
Weld joints and application of zinc rich paint on
galvanised surfaces.
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
13.
Stringing work, tubular bus work and power connections.

(i)
(ii)
(iii)
(iv)
(v)
(vi)
14.
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
Insulators
(i)
15.
Physical checks for finish / polishing / scratches.

Electrical clearances checked.
Testing of torque by torque wrenches on all bus bar
power connections and other accessories.
Milli-volt drop test carried on all power connections.
Sag and tension checked on conductors.
Measurements of ID / OD of busbars taken.
Visual examination for finish, damage, chipping off

creepage distance has been done.
YES/NO
Transformers
Precommissioning test results
(i)
IR. Values. Of different phases has been measured.

DC Winding resistance (in ohms) has been measured.
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
16.
Oil test results have been taken.

Magnetising current has been taken.
Short ckt. Test has been carried out & results are
satisfactory.
Vector Group has been verified.
Magnetising balance has been checked.
Specified protections have been provided:

Relay settings made.
WTI/OTI calibrated with hot oil bath and std.
thermometer
Fittings
Check if following fittings are provided with transformer.
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
17.
Plain Oil Gauge

Silica Gel Breather
Pressure Relief vent.
Pocket on tank cover for Thermometer.
Valves.
Earthing Terminals.
Rating & Terminal Marking Plates.
Lifting Lugs
Rollers
Air Release Plug
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
For early release of supply by the State electricity Board

(i)
Payment deposited well in advance.
(ii)
All the erected equipments in substation got inspected by

the Inspectorial wing of CEA and permission obtained
for energisation.
YES/NO
18.
Before metal spreading, substation is levelled to the required YES/NO

level, watered and rolled with light roller.
19.
Check if the following checks have made during Erection.

(i)
(ii)
(iii)
(iv)
20.
Erection carried out either proper tools.

Correct phase sequence & location of operating
mechanism.
Tightening of bolts / nuts with torque wrench.
Proper earthing of isolator points / Switch cubicles bas
been provided.
Check if the following are available for testing and

commissioning.
(i)
Factory test reports of the equipments.
(ii)
Erection key diagram.
(iii)
Schematic diagram.
(iv)
Megger 500 V 1000 M. Ohms : 10 K.V. 100000 m.
Ohms.
(v)
Digital multimeter
(vi)
(vii) Heating arrangement with standard thermometer
(viii) Kelvin Resistance Bridge with Battery
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
21.
General checks before applying for CEA clearance.

(i)
(ii)
(iii)
(iv)
(v)
Whether equipment erection is completed.

Whether fire protection wall provided.
Whether transformer LV neutral is grounded.
Whether transformer tank is grounded.
Whether double earthing provided for body of
transformer.
(vi)
(vii)
Heating arrangement with standard thermometer
(viii) Kelvin Resistance Bridge with Battery
(ix)
Whether adequate lighting is available.
(x)
Whether approach is safe.
(xi)
Whether transformer oil level is OK.
(xii)
Whether transformer breather is fixed and silica gel
colour OK.
(xiii) Whether all precommisioning checks carried out and
results satisfactory.
(xiv) Whether statutory clearance obtained.
(xv)
Whether other yard equipments are OK.
(xvi) Whether all protection checks on HV / LV done.
(xvii) Whether relays protection set properly.
(xviii) Whether earthing of live parts removed.
(xix) Whether energy meters installed & calibrated. (indicated
date of calibration and meter details).
(xx)
Whether equipment is safe for energisation.
(xxi) Whether first aid facility is available.
22.
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
General Checks
(i)
(ii)
(iii)
(iv)
All the necessary testing kits and accessories are

available at site.
All erection hardwares foundation bolts earthing strips
etc. are available.
Qualified welder is available at site.
Welder qualification test certificate and welding
procedure is approved.
YES/NO
YES/NO
YES/NO
YES/NO
________________________________________________________________
BIBLIOGRAPHY
(1)
Bidding document for turn key packages of S/Stn. Associated with Vindyachal
Stage-II. Transmission system, Technical Specification Part 2 of 2.
(2)
Tech. Specification for Auxiliary Distribution Transformer and Isolator, Vol. II.
(3)
Manual on S/Stn.; Chapter 1 on specification for Sub-station Battery, Charging

Equipment and D.C. Switchgear by CBIP (Tech. Report No. 79).
(4)
Instructions for Standard Stationery battery by The Standard Batteries Ltd.
(5)
Standard Battery Technical Service Manual by Standard Batteries Ltd.
(6)
Construction Manual, Part-I, S/Stn. Construction Vol. IV, Section-IV : Auxiliaries

by SRTS.
(7)
IS : 1886-Code of practice for installation and maintenance of Transformers.
(8)
IS : 1651 Stationary cells and Batteries, Lead Acid type (with Tubular Positive
Plate).
(9)
IS : 1652 Stationary Cells & Batteries, Lead Acid type (with plante positive
plates).
CONSTRUCTION MANAGEMENT
DEPTT.

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FOR INTERNAL CIRCULATION ONLY

Power Grid Corporation of India Limited

DOCUMENT CODE NO. : CM/AP/AUX. PKG. (ELECT.)/96

Management Deptt. has come out with further 3 volumes of users

NEED FOR PROVIDING BATTERY

CHOICE OF BATTERY TYPES

VARIFICATION IN THE CHOICE OF FLOAT VOLTAGE 11

RECEIPT & STORAGE OF BATTERIES CHARGERS

ERECTION AND COMMISIONING

FIELD QUALITY PLAN

PREPARATIONS BEFORE ERECTION &

PRECAUTIONS DURING BATTERY INSTALLATION

RATED AMPERE-HOUR (AH) CAPACITY

PRECAUTIONS DURING INITIAL FILLING OF

CALCULATION OF BATTERY CAPACITY

FACTORS AFFECTING BATTERY LIFE

BEING CONVERSANT WITH THE ACCESSORIES

CATEGORIES OF SUBSTATION LIGHTING

MINIMUM LUX LEVELS

DISTRIBUTION SCHEME OF LIGHTING

RECEIPT OF MATERIALS AT SITE

FIELD QUALITY PLAN

PAINTING FOR SHOP MADE ITEMS

TEST AND TEST REPORTS

EQUIPMENTS IN 11/33KV/415V SUBSTATION

SUPPLY AND ERECTION OF EQUIPMENTS

PRECOMMISSIONING TEST FORMATS FOR

PRECOMMISSIONING TEST RESULTS

INSPECTRION BY CEA TO ENERGISE THE EQUIPMENT

RELEASE OF SUPPLY BY THE STATE ELECTRICITY

RECEIPT AND JOINT INSPECTION

PROGRESS REPORTS AND REVIEW MEETINGS

Need for providing battery supported dc system

Besides the A.C. Supply which is not perfectly reliable another

Supply to trip coils and closing coils of switchgears or

Indication: Indicating lamps, facia

For energising the holding and operating coils in control

For power supply to communication including PLCC

For providing power supply to EDP System.

For emergency DC lighting.

Electric impulses for impulse clocks.

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The most commonly used type of battery in electrical

Although some indigenous manufacturers have initiated

Lead acid cells are of three designs based on the

These plates are of the following types

Plante positive plate with pasted negative plate,

Tubular positive plate with pasted negative plate and

Pasted positive plate with pasted negative plate.

temperature of operation, quality of maintenance have a

therefore on the choice of the type of battery.

for short durations as

required in unattended substations whereas the cells with

figures for the three designs are indicated in Table 1.

Initial Cost (Percentage)

performance and tests for cells of the three types dealt

Flate pasted Cells

The following parameters have to be selected

to meet the specific requirements in each application

variation acceptable for the loads, load

cycle and the minimum voltage during the discharge cycle

Voltage and number of cells in the battery and

Rated Ampere-hour capacity.