EHV SUB

STATION
Construction – &
Commissioning.

Mr. A. S. DAITHANKAR,
Retd. S.E. MSETCL, Pune
In the last lecture we have seen the lay outs the
positioning of various equipments in the sub stations
also we have seen the equipments in the sub
substations.

Your are aware of purpose of each equipment in the

sub station.

In this session we will discuss mainly construction

and commissioning of these equipments.

The purpose of equipments will be explained in short

Construction and commissioning of
sub station

Construction and commissioning of sub station is

a subject describing the actual execution details.
1. These sub station land is initially selected and
the final level to be kept for construction of sub
station is decided on the basis of contour
survey of the sub station land. So that the land
development is carried out economically.
2. The land development is then carried out
accordingly
3. The sub station equipments and gantry
foundations are then cast. The control room is
also constructed as per drawing.
4. The construction of sub station includes some
of following activities.

• The arrangement of 3 phase supply upto 200

KVA
• Erection of sub station columns and beams.
• Stringing of various buses in the sub station.
• Erection of equipment structures and
equipments
• Erection of equipment is control room
• The earthing mesh and earthing electrodes
work
• The equipments are connected to each other,
to bus, etc. by carrying out jumpering work as
specified in the lay out .
• The clamps and connectors are used while
jumpering
• Commissioning of breakers, isolator alignments
are carried out.
• Battery charging, charger commissioning
making DC supply available for testing
purposes.
• Commissioning of C & R pannels relays etc.
• The transformer erection filteration and testing
• Lightining in control room and switch yard.
• Metal spreading
• Commissioning after proper testing is carried
out.
Erection and commissioning of Sub
Station Equipments

1) Before Erection of Equipments all the civil

foundations for them are already cast as per
the sub Station layouts. The Foundations bolts
for Equipments grouted.
2) The approach roads are made to take the
crane, truck, etc near the foundations.

Once above said activities are completed the actual

erection of equipments Starts.
The main Equipments in any sub Station
involving No. of activities during
erectioning and commissioning are.
(1) Circuit Breakers
(2) Power transformers

(1) Circuit Breakers SF6 circuit breakers are now

used in EHV Substations SF6 gas is used for
arc-quenching purpose, and as a dielectric
material.
 The purpose of breaker is to isolate the faulty
Equipments / Lines from Healthy system and maintain
the system stable. They are operated through
protective relays on the C & R pannels. The control
wiring is connected between breaker and C & R
Pannels. The breaker can be operated from remote
pannels through operating switches on pannel or locally,
electrically, manually .

(a) Transportation of breaker form store yard to

foundation is carried out with the help of crane
and trucks.
(b) Unpacking - All the packages containing various
materials of breaker should be unpacked,
checked for any shortages or damages of
materials.
(c) In case of breaker where the mechanism box
serves as the base for the pole Unit assymbly,
the mechanism boxes are first erected on
foundations and levelled on foundations and
the foundation bolts are tightened. In other
cases steel structures for mounting pole
assembly are first erected on the foundations,
levelled and the foundation bolts are tightened.
(d) The pole Unit assymbly is then carefully lifted by
crane, after properly tying it with ropes and fixed
on the base structure with the help of foundation
bolts.
(e) The pole unit assymbly is then connected to
operating mechanism with the arrangements
available for individual breaker.
(f) In case of pneumatically operated breakers the
air piping is connected between Air compressor
operating mechanism & pole unit. Assymbly.

These Air pipe Lines of copper of required

diameter and wall thickness, are laid care fully
through cable trenches with proper supports to
avoid the vibrations.

The desired air pressure required for operating

the breaker is then filled in these pipes from
compressor.

The pipe Line is checked for any air leakage

with soap water.
(g) Connection of SF6 piping
The SF6 gas pipe Lines are connected to pole
Unit assymblies after checking that positive
pressure of SF6 gas is maintained both in pipe
lines as well in pole assymbly units.

The SF6 gas in filled in to pole assymbly units

and pipelines from the gas cylinder through gas
filling device to desired value for operation of
breakers.

The gas leakage should be checked with the help

of gas leakage detector, soap water.

(h) In Breakers slow closing and opening operations

are carried out to measure contact travel,
penetration of contacts, travel of mechanical
Linkages in operating mechanisms.
(h) In Breakers slow closing and opening operations
are carried out to measure contact travel,
penetration of contacts, travel of mechanical
Linkages in operating mechanisms.

(i) Inter phase wiring

The Inter phase wiring is carried out as per wiring
diagrams of breaker control units, The cables are
laid in trenches on cable trays properly supported,
the cable glands should be used, the lugs are
crimped on wires and connected on terminals.
The connections are then tightened properly.

Commissioning: -
(1) Check operations of Air pressure switches for
alarm trip, lockouts, compressor operations at
their recommended values.
(2) Check the above operations of gas density
monitor for lockout, trip, operations of breakers.

(3) The AC DC supply should be extended to

breaker and the various timings. Like closing,
tripping, close trip etc. are measured by
connecting the timer. It should be ensured that
these are within the recommended ranges.

Once all these tests are carried out the Insulation

resistance of breaker in open and closed conditions
should be measured & breaker can be put in to service.
 Power transformers.
The power transformer is very important and costliest
equipment in the sub station, it should be handled
carefully and erection should be carried out
systematically ensuring proper checks at every step.
Following precautions should be taken before taking up
the erection.

1) The person going on the transformer tank should

not stand on any part of Diaphragm of Diverter
switch.
2) No one should be allowed on the transformer top
unless he has emptied his pocket.
3) All the tools and spanners should be securely
tied with cotton tape. So that there will not be
dropped inside the transformer tanks
 Power transformers.
4) All components are cleaned out side
separately before erection.
5) Fibrous materials should not be used for
cleaning. The presence of Fibrous material
suspended in oil will affect the electrical
properties of oil.
6) Interior of the transformer should not be
exposed to atmosphers as far as possible to
avoid ingress of moisture in the transformer
insulating paper, windings etc. In case of
sudden change in weather bringing rain,
provision must be made for closing the tank
quickly and pressuring it with N2 so as to
preserve the insulation.
 Power transformers.
7) Naked Lights and flames should never be
used near the oil Filled transformers.
8) Smoking, should not be allowed when the
person is on transformer top cover, when the
cover plats are open & also in the vicinity oil
processing plant.
The procedure for erection and commissioning is as
follows.
1. Oil filled transformer
Transformer of 132 KV class insulation even up
to 50 MVA capacity and 220KV class up to 25
mvA capacity are generally dispatched and
transported with oil filled up to core level. The
remaining oil required for further topping up etc is
dispatched in to sealed oil barelles.
a) The transformer is unloaded with rollers on the
rails, and should be taken into it's proper position
so that the jumpers from H.V. / LV side will be
easily connected to the respective bushings.

b) The transformer rollers should locked by fixing,

locking clamps on rails near them.

c) The accessories of the transformer should be

transported near the working place and checked
as per packing list. The accessories should be
checked against damage if any.
d) The operating Valves should be properly cleaned
and checked for the operation many times, before
fitting on transformer. This is very important
because once the valves are fitted on the
transformer in various piping, it should be
possible to open those fully without any trouble
other wise it may lead to the obstruction or even
stoppage of oil flow in future and it is very difficult
to remove the valves once the oil is filled. It
required draining the oil

e) The T & P required for erection is mainly crane

with sufficient number of slings, polypropolin
ropes of varies sizes. The common T & P such as
spanners pipe wrench, Hexa with blades, etc
should also be available as usual.
f) The turrets should be fitted on the main tank. The
turret C.T.'s should be checked, before erection
for their.
i) polarity
ii) Continuity
iii) Ratio
Once the turrets are fixed the bushing should the
taken of erection.

The Erection of Bushings.

1) The bushings should be thoroughly cleaned from
outside & inside with cloth & with C.T.C to remove
the dust.

2) It should be tested for insulation resistance, tan

delta before erection.
3) The locking Pin to lock the lead coming from the
winding should be checked and made available
during erection on site.
4) The bushing should be properly tied with ropes
and should be lifted with the help of crane and
fitted on the main tank turrets. The seat of the
bottom portions of bushing on the winding should
also be checked through inspection cover. The
lead from the winding should be taken through
the middle hollow portion of the bushing and
Locked on the top of bushing with lock pin. Then
the clamp is fitted on the lead & Jumper is
connected to this clamp.
5) Once the bushings are erected other accessories
like Headers, Radiators, Conservators, piping
between tank, conservator & turrets etc. Should
be connected.
H) Buchholtz relay -
a) The inside contacts for alarm and trip operations
should be untied before erection as they are tied
up during transportation to avoid the damage.
b) The Continuity of contacts for alarm and trip
operations should be checked before erection.
c) The Buchholtz relay, should be fixed in the piping
with it's arrow marked towards conservator.

i) The PRV :- The PRV should be tested for its

operations before fixing.

j) Oil Surge relays: - There are fixed in the oil piping

for Divertor switches. Contacts for Alarm and Trip
should be checked before fitting.
k) The MOG :- (Magnetic Oil Gage) Showing the oil
level is also checked by operating it externally.
The contacts used for low oil level should be
checked for continuity.

l) Once all these accessories are fitted the nut bolts

should be tightened to prevent the oil leakage

m) Oil filling and Filtration of oil.

a) T & P Requirement
i) Oil lank of adequate capacity.
ii) Filter machine of preferably 6 KL/hr circulating
capacity and capable of achieving full vaccume of
5 torrs with main and roots vaccume pumps.
iii) The separate arrangement for evacuation of N2
Gas inside the transformer tank with
simultaneous filtration of oil should be available
on the filter machine.
iv) The filter papers should be cleaned and replaced
if necessary
v) The heaters provided on the filter machine should
be checked
vi) The LT Cable of adequate size to take the load of
filter machine should be laid from ACDB with a
main switch near filter machine.
vii) The rubber hoses, flanges of adequate sizes
should be available to fit on the machine, storage
oil tank and transformer as required.
The oil storage tank, the filter machine should be
properly arranged and AC supply should be
connected to filter machine
viii) The oil BDV tester upto 100 Kv range should be
available.

Oil filling
1. Oil from the sealed barrels should be taken in the
storage tank through filter machine.
2. The oil storage tank should be cleaned from
inside before oil is taken in to it.
3. Once the oil is taken in the storage tank it should
be filtered till the desired values of BDV and water
content as recommended by the manufacturer
are achieved.
4 Once the oil is ready it should be filled in the
transfer tank from the bottom valve and the full
transformer upto desired level in the conservator
including headers, radiators should be filled.
5. The radiators should be flushed with the oil to
remove the dust, foreign material from them if any
before filling the oil.
6. The BDV of the existing oil in the main tank of the
transformer should be checked before oil filling.
7. Now the oil leakage from all the joints should be
check and attended by tightening the nut bolts
Oil filtration
The oil filtration should now be carried out by circulation
of oil through filter machine. The inlet and out let pipes
from machine to transformer should be changed as per
requirement after certain hours.

All the floating impurities from the oil should also be

removed during filtration.
Finally the hot oil should be sent to the transformer from
the bottom so that transformer windings get heated.
Filtration should be continued till in desired values of oil
parameters and insulation resistance of windings are
achieved.

The oil temperature in the filter machine should be

maintained generally 60 to 65 Degrees Centigrade.
The diverter switch is also filled with filtered oil of desired
BDV as per manufacture's directions.

Finally oil should be tested for different parameters as

per IS insured that recommended values are achieved.
The IR values of windings and PI values should be
checked and should be as per the recommendations of
manufacture.
The driving mechanism and deverter switches are
connected with connecting rods. The tap positions on
the driving mechanism and diverter switch should be
match.

The electrical wiring as per wiring diagram between

transformer accessories and transformer mechanism
box should be completed.

The wiring should be extended to control and relay

panels

The neutral bushings of the transformer are separately

earthed with copper strip at two separate earthing pits.
Other earthings to transformer body, fans, DM, etc. are
provided with MS strip
The pre commissioning testing of the transformer is
carried out. The operations of transformer breakers
through protective relays are checked.

Nitrogen gas filled transformer

The activities upto checking and cleaning of the
accessories, erection of transformer turrets, bushings,
piping, cooling system are same as in case of oil filled
transformer.

However at this point the filter machine is introduced for

vaccume pulling from inside the transformer tank.
Following point are to be checked before pulling the
vaccume

1. The pipes going to radiators and conservator

should be blanked with blanking plates so that
vaccume will not be applied to them.

2. The silica gel breather with gate valve should be

fixed between the piping going to conservator to
release the vaccume after oil filling

3. The diverter switch chamber and the main tank

should be connected by hallow pipe so that both
will be evacuated simultaneously
Vaccume pulling

Vaccume should be pulled from the transformer tank up

to the desired value recommended by manufacturer and
should be maintained for atleast 24 hrs. After checking
and attending the leakage's if any.

Oil filling
1) The oil should now be filled in to the transformer
tank under vaccume. The vaccume pulling in the
tank will avoid chances of air getting trapped or
forming pockets. The oil is first filled upto core
level in the main tank through filter machine.

2) This oil is filtered in storage tank before filling in

the transformer. The oil is filled after the required
values of BDV and water content are achieved.
3) Once the oil is filled upto core level and windings
and core are immersed under oil the vaccume is
release through breather fitted as said above by
opening the gate valve.

4) The pressure equalising pipe between diverted

switch and main tank is removed. Then oil is filled
in the remaining part of the transformer. The oil
filteration is carried out after the oil filling is
completed till the desired results of oil and IR
values of transformer are achieved. The testing of
the transformer is then carried out as in case of
oil filled transformer. The transformer is ready for
commissioning. The air venting should be carried
out before commissioning
Conservatior with air cell

Now a days the conservators with air cell are used

instead of conventional ones.

The contact between the atmospheric air and the

transformer oil is prevented by air cell made of synthetic
rubber component.

The principal of such system is that when the oil level in

the conservator tank falls or rises due to contraction or
expansion of oil. The breathing takes place through
silica gel breather and the air cell.
 Isolators two types
1) WEB - used when the particular equipments is to
be earthed. Normally up to 220 KV Sub Station
these isolators are used on line side to earth the
line when under shutdown for any work to be
carried out.
2) Not operated on load; they are operated when
they are disconnected from load side and source
of supply and current may be only due to
capacitive / charging currents of transformers and
lines
3) To ensure that the isolators are not operated on
load it is necessary that they are suitably
interlocked with connected breakers. The
isolators should be operated only when breaker is
in open position.
4) For construction purpose they are grouped as

A) Three post, centre post rotating double break

isolates.

B) Two post (rotating) single break isolator.

A) The center post carries moving contact arm with

contacts assembled at the extrem ends. The
moving contacts engage the fixed contacts
mounted on other post insulators on either side.

The rotating center post insulators of all the three

phases are connected with the operating rods so
that the simultaneous movement of each contact
arm is ensured.
 Rotation of center post insulator is effected
through a lever at the base of each of it. these 3
leaves are connected to by operating rods and
are driven from one post by these operating rods
through a driver rod connected between operating
mechanism (fitted on isolator structure) and
driving post insulators. They can be hand or
motor operated.

B) Single break isolators operated where in both the

post insulators rotate causing movement of
contact arm. The contact arm is devided in two
parts, One caring male and the other female
contacts. These are rotated through a down rod
between operating mechanism on structure and
operating mechanism between two post
insulators.
 Only one phase isolator can be operated
mechanically at a time. However for simultaneous
operation electrical operation is necessary or can
be achieved mechanically as in case of double
break isolators.

Earth Switch
5) Earth switch usually comparies of a vertical
break switch arm with the contact at the extrem
end and engages with fixed contact fixed on the
post insulator on the line side. They have
saperate operating box and operating system.
Mechanical interlock is provided between main
and earth swithches so that earth switch can be
operated only when main isolator is off and vice
versa.
b) These isolatos are operated form local as well
from remote ends (i.e. pannels) The control wiring
is to be connected accordingly between pannels
and the operating mechanisms of isolators

c) The ON & OFF indications of isolators can be

brought on the panels through aux. switches
provided in operating mechanisms which
operates while operation of the isolators.

6. Arcing Horns :-
These are provided for insulation co-ordination.
The use of arcing horns is avoided where the
insulation strength between poles (i.e. phases)
and between two poles of same phases when the
isolator is open, is higher than that between live
points of poles to earth.
7. Construction and commissioning
a) The structure is assemble according to the
drawing provided and levelled properly.

b) The isolator base chaises are mounted on this

levelled structure and fixed with nut bolts. The
chassis are also levelled so that top plates of
chassis where the post insulators are fixed are at
the same level.

c) The post insulators are then mounted with on top

plates of chasis with fixed contact and
connecting arms (isolator blades), fitted on them.

d) The operating mechanisms are then fixed on the

structurs and the operating roads fixed between
three phases.
e) The isolator alignment is carried out first on each
phase saperately and commonly for three phases
through the operating mechanisms.

f) This alignment is first carried out for manual

operations and then for electrical operations
through motors locally.

g) The position of limits switches are adjusted to

mach the travel of isolator blades while closing
and opening. This is when the operation is
through electrical motors.

h) The oilling greasing of gear boxes and moving

parts on the mechanism is carried out where ever
necessary.
i) The petroleum jelly is applied to contacts for
easy operations and protection against corrosion .

j) The jumpers are then connected to the isolators

and final operations are checked from local as
well from remote end.

k) It is also checked as to whether the proper ON -

OFF indications appear on the pannel.

l) The megger values between phase and earth as

well between phase are measured.

m) Some times contact resistance is also measured.

The isolators can now be taken in to service.
1. Voltage transformers

1. Voltage transformer step down the system

voltage to sufficiently low values for

a) indication of voltage conditions

b) Metering of exchange of energy
c) Relaying
d) Synchronizing

2. The indicating instruments, meters, relays are

designed for voltages as obtainable from
secondary sides of the voltage transformers.
3. The calibration of these instruments is however
according to primary voltages of voltage
transformer.
4. Construction and commessing
1. Supporting structurs assemble as per drawing
2. They are fixed on the foundation and levelled
properly.
3. The voltage transformer mounted on the structure
by fixing with the nut bolts.
4. The meggare values checked
5. The polarity and ratio checked
6. The earthing is checked especially the second
terminal of primary winding is earthed.
7. The oil level in the voltage transformer is checked
8. If every thing is correct the voltage transformer
can be commissioned after connecting the
jumpers.
5. Current transformers

Measurement of the current is one of the most frequent

operations for following reasons
a. Indicating ammeters
b. KWH & KW meters
c. protective relays
d. telemetering
If current exceding several 100 of amps. are circulating
through the equipments continuously the best solution
is to obtain replica of these currents in primary circuits.
This is achieved by means of current transformers

The current transformers are connected in series in

network and is intended normally to operate with rated
current in primary circuits
 The secondary winding of CTs connected to
measuring instruments and relays supply the
current to them proportionate and in phase with
the primary currents flowing in the network.

The Construction method is same as that of

voltage transformers

5. Before commissioning ratio, polarity and the

currents in the secondary circuits are checked,
the oil level is checked, meggar values are
checked. The CTs can be commissioned after
connecting the jumpers.
6. Lightning Arrestors
1. The LAs are provided on lines and for
transformers.
2. These are connected directly to line or bus
connected to transformer.
3. The purpose is to earth the lightning surges to
earth and save the sub station equipment's and
the transformers from the over voltages causing
due to lightning.
4. The Lightning Arrestors should be effectively
earth separately
5. Construction - The supporting structures are first
fixed on foundation and leveled properly. and then
Lightning Arrestors are fixed on the structures.
The search counter provided should be
connected.
6. Surge counter counts the surges passed through
the Lightning Arrestors as well monitor the
leakage current under normal conditions.

7. C & R Pannels
The C & R Pannels are mounted in control room
the main functions are
a. To control the operations of breakers under
normal and abnormal conditions of system
b. Provide indications of status of equipment's in the
switch yards.
c. To indicate the current in the system, bus voltage,
line voltage, temperature of transformer windings,
oil etc.
d. Measurement of energy through energy meters
e. The annunciation of the fault in the sub station or
any abnormal conditions is seen on the
annunciator facia, alarm for trip and non trip
signal are given

2. The C & R Pannels are mounted on the floor in

control room near cable trenches so that cables
can be taken in conveniently
3. The C & R Pannels are arranged in rows in the
sequence according to that in switch yard.
4. Earthing is provided for each C & R Pannel
5. Various relays are provided on this pannels for
protection of equipment's like transformers and
lines etc. The appropriate protective relays are
provided on the pannels for protection.
6. The relays are tested with testing kits and their
characteristics are checked. The various
functions of relays are also checked.
7. Once the testing is completed the settings are set
on the relays according to proper protection co-
ordination in the system as per requirement.
8. The operation of breakers, isolators are checked
from the control switches provided on the
pannels.
9. The indicating and measuring instruments like
ammeters, voltmeters, energy meters are
calibrated. It is also checked by primary injuction
as to whether the indicate the proper values.
10. It is checked as to whether the status of
equipments in this switch yard is shown correctly
on the pannel.
11. The lighting in pannels should be checked, heater
should be ON
12. After these checks the pannels can be
commissioned and put into service.
 DC Supply
a. The DC supply is required in the sub station for
signaling remote position control, remote indications
and similar purposes. The AC supply is not always
reliable hence in no case of absence of AC supply the
important purpose of control of CB in event of fault in
sub stations, on EHV lines should be affected.
b. Fixed storage batteries can be used for these purpose.

They are lead acid cells

Complete DC equipment's for sub station may be
divided in to following parts.
a) Storage batteries and accessories
b) Charging equipment's
c) DC DBs
 DC Batteries
The ratings of the batteries used is as follows

1. 132 KV sub station - 110 V (55 Cells), 200 Amp Hrs.

2. 220 KV sub station - 220 V (110 Cells), 300 Amp

Hrs.

3. 400 KV sub station - 220 V (110 Cells), 500 Amp

Hrs.

5. The stationary batteries under normal conditions do

not deliver the energy but provide the same as and
when required hence should always be in readiness
 6. Accessories
a. Cell testing voltmeter
b. Hydro meter
c. Thermometer
d. Acid jugs for toping the cells
e. Rubber gloves
f. rubber apron
g. Tool box
h. battery log hook
i. distilled water
J. distilled water plant
 Erection and charging procedure of DC
batteries
1. Battery room
a. Battery room should be well lit with acid proof fitting
b. The room should be closed no direct sun lights on the
cells
c. Exhaust fans should be provided in the room to exhaust
the gases produced during initial and trickle charging
d. Entry for fresh air should be given from bottom of the
room by providing a small window with wire mesh
e. The floor and side walls up to 5 feet height should be
provide with acid proof tiles
f. One basin should be provided with water tap for washing
hands and preparation of distilled water
g. The distilled water plant is fitted near the basin on a wall
so that distilled water can be prepared as and when
required. This is required for levelling the electrolyte the
battery cells
 Initial preparations and precautions
before battery erection and charging
a. The battery cells should be unpacked carefully without any
damage to container. The cells should be lifted from the bottom
and not by holding the battery terminals. after unpacking the
batteries should be cleaned. Any dust or other material.
b. The electrolyte containers are packed in wooden packages
these wooden packages are not to be removed even while
pouring the electrolyte in to battery cells
c. The sulfuric acid is the electrolyte used in battery cells. The
supplied sulfuric acid is concentrated to specific gravity around
1.8 to 1.9 hence has to be diluated to specific gravity of 1.2 by
adding acid to distilled water and not vice versa. In a clean
plastic container and should be rinsed by glass rod. The
solutions should be allowed to be cooled for overnight and
specific gravity and temperature should be checked. If the
required specific gravity is not obtained add acid or distilled
water as the case may be till correct specific gravity is
obtained.
d. The proper care should be taken to wear apprans, gloves,
protective goggles while preparing the solution.
 Specific Instructions:
j) Arrange the wooden stands as per the battery layout
drawing supplied and place underneath the legs of
the stands stand insulators supplied, which are
normally PVC sheets. 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 terminal(s) of anyone cell, adjoin the
negative terminal(s) of the cell throughout the
battery.
iv) 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 terminals(s) of the end cell
of 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.
v) 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 connector. Connect
the inter -cell / inter-row / inter-tier connectors sufficiently
tight, to avoid any loose connections and again smear
petroleum jelly over 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.
vi) Connect the external cable from the battery charger, to
the respective end terminals of the battery bank, once
again ensuring the polarities. The positive terminals of
the charger has to be connected to positive of the battery
bank and similar is the case of negative to negative
connections.
vii) 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 should be left on
top of the cells at any time.
Filling of Electrolyte
A. 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 applies to
our cells of capacities 100 AH & above. Lift the electrolyte
carboys containing dilute sulphuric acid "(supplied ready
mixed or prepared previously, as the case may be
alongwith the packing cases in-tact 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. The level of electrolyte in each
cell should be adjusted to correspond to the top red-mark
on the float-guide. The bottom red-mark indicates the
minimum level below which electrolyte should not go.
B. After filling-in with electrolyte, leave the cells idle for a
period of not less than 12 hours and not more than 24
hours, until the electrolyte temperature falls down
nearest to the ambient temperature. 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 for initial filling. Again replace the vent plugs
without tightening. The battery is now ready for first
charge.
First Charging
1. Check again the polarity of inter-celi/row/tier
connections. Ensure that all fastenings and connections
are tight. 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
terminal provided on the charger. If the deflection is in
the positive (clockwise) direction, the connections are in
order. In case of reverse deflection, the leads should be
interchanged 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 of the DC output
switch of the charger.
2. Before placing battery on charge check and record the
open circuit voltage of every cell. After this connect the
battery for boost charge at the rate specified for about
80 hours by using direct constant current. After 80
hours of charging disconnect the battery and give it a
rest of 4 hours. The battery is to be charged for a
further period of 40 hours at the specified rate. Specific
rate is 15 amp for 300 Ah & 10 Amp for 200 AH

As soon as the battery is on charge take another set of

voltage readings and enter these readings opposite the
open circuit voltage readings. If the battery is connected
upright and there are no reversed cells, proceed with
the charge. During the first charge take individual cell
voltage, specific gravity and temperature readings
every eight hour and record. First charge input 1800 AH
for 300 AH & 1200 AH for 200 AH batteries
3. The cells are considered to be fully charged when
values of cell voltage and specific gravity of electrolyte
corrected to 27°C remain constant for three
consecutive hours at the end of approximately 120
hours of charge.
4. At no stage during charging, the temperature be
allowed to exceed 50° C. If the temperature tends to
rise beyond 45° C, 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 shall be correspondingly increased so that at
the end of charging, the specified ampere hours input
has been put into the cells.
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.
 At places, where high ambient temperature normally
prevails and where electrolyte temperature limit of 50°C
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.
5. If the electrolyte level goes down the specific limit
during charge, the same may be topped up by adding
1.200 specific gravity acid as originally filled in.
6. At the end of charging the specific gravity of the
electrolyte is to be adjusted to 1.200 +/- 0.005 at 27°C.
If the specific gravity at the end of charging is above
1.200 add distilled water and if it is below 1.200 add
1.400 specific gravity acid and charge for a couple of
hours and check the gravity again.
7. After the cells have cooled to ambient temperature
adjust the level by withdrawing electrolyte from the cell.
8. The top and. sides of the cells should be wiped clean
and dry. Any acid dripped or spilled on stand and. floor
should be neutralised and cleaned up.
9. Towards the end of charge, all cells start gassing freely.
The voltage will reach a final value of 2.50 to 2.55 V 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
specific ampere hour input is fed into the battery that
the cell are freshly gassing during charging
 FOLLOWING POINTS TO BE NOTED AND
INVARIABLY OBSERVED
1. Smoking or use of a naked flame in the battery room
should be strictly prohibited.

2. Ensure correct polarity between adjacent cells between

the battery and the charging source. Charging the cell
or battery in the wrong direction will ruin it.

3. Never make the specific gravity adjustment on a cell

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

4. Use calibrated meters for measuring current, cell

voltage, specific gravity and temperature.
5. The Performance of a battery during its service
depends to a great extent on how completely the initial
or first charge is carried out. Never therefore, terminate
the charge until the specific ampere hour input is put in
the battery even though the cells may show constant or
higher specific gravity readings, before completion of
full Amper-Hour input. .

a. After initial charging 4 to 6 hrs rest is given

b. Then the battery is discharged through water load at
the rate of 10% of its capacity till either the voltage of
each cell is reached upto 1.8 volts or specific gravity to
1.1 which ever is earlier for 3 consecutive readings. The
time taken for this discharging is measured. If it is 10
Hrs or more then full capacity of batteries is obtained.
c. If the capacity is not obtained the same procedure of
charging and discharging is carried out once again till it
is obtained.
d) After the capacity of batteries are obtained they are
again charged at the rate of 10% of 10 hrs capacity of
battery till gassing point, and at the rate 5% of 10 hrs
capacity till are fully charged.
The batteries are fully charged when they gas freely
and cell voltage and specific gravity remain constant till
3 consecutive hourly reading.
The batteries are now ready for putting them into
service.
The batteries are then kept on trickle charge in float
mode at 2.2 to 2.3 V per cell this is required to
compensate for internal discharging of battries due to
internal resistance.
 The batteries then supply the load in event of failure of
AC supply and DC source from the charger.

Batteries for PLCC

The PLCC pannels required 48 V DC supply for their
operations the battery set of 24 cells of 100 AH is used
for this purpose The erection and commissioning
procedure are same as that of sub station batteries
 Battery chargers
a. Two modes are available, Boost and float

b. Chargers are required for

i. charging the battery sets - through boost charger
ii. The continous trickle charging the batteries during
service

c. Supply voltage is 415 Volts 50 Hz.

d. Boost charger is used for initial charging and

discharging of batteries
e) Rating :- Higher current rating upto 20 amps to 50
amps depending on the requirement.

f) Float charger -
i. For providing load current
ii) The trickle charging for battries

Rating :- upto 10 to 15 amps depending upon the

requirements

g) The charger is installed in charger room near the cable

trench so that the cable can convinently be taken in

h) The load test on boost charger is taken for rated current

by putting external load on it. The charger is kept on
load for 4 to 6 hrs to check its performance.
i) The battery terminals are then connected. The charger
can be put in to service for battery charging

j) The float charger is also taken into service and can feed
the load.

The boost charger can function as the float charger in

event of failure of float charger.

48 Volts battery charger us used of PLCC

Rating :- Boost - 65 Volts, 12 to 24 amps depending upon
the requirement
Float Charges :- Voltage 48 Volts +/- 1%
Current 10 to 30 amps depending upon requirement
The commissioning process is the same as that for main
battery charger
ACDB :-
1. ACDB is used for supply of AC power to various load
circuits in the sub station

2. The ACDB has two in comers and bus coupler

switches and number of outgoing circuits with proper
ratings

3. ACDB when received on site should be unpacked and

checked for any visual damage of any component.

4. ACDB should be properly cleaned before installation

5. The bus provided in ACDB should be meggared with all

in comer and out going switches in open position
ACDB is mounted in ACDB room near cable trench so
that cables can be taken inside conveniently

The cable from sub station transformer (2) are

connected in two numbers of in comer switches of
ACDB as two independent sources.

The two sources can be paralleled through bus coupler

switch or separately operated.

Suitable inter locking is provided on ACDB so that bus

coupler can not be made ON unless one in comer
switch is OFF.

Parallel operations of both sources is checked before in

comer switches are made ON.
After checking as above the ACDB can be put into
service.

The ammeters showing the in comer and outgoing

currents, the voltmeter showing the in comer and out
going voltages are provided
 Lighting System

1. Internal electrification of control room is carried out as

per requirement

2. The switch yard lighting is provided on masts with HPSV

lamps of varies wattage ranging from 150 to 800 watts
depending upon the requirement.

3. The lighting is controlled centrally from a separate ACDB

in control room .
 Earthing
1. Earthing is used
a To provide protection against damages to plant
equipments and personnel associated with the use of
electrical energy.
b. To maintain the uniform earth potential nearly zero all
over the ground under and around the sub station. This
is to ensure that

1. All parts of equipments connected to earthing systems

should be at ground potential

2. Operators and attendants should always be at ground

potential
3. The sub station earthing is in the form of grid,
comprising of number of squares and rectangles
meshes of earthing conductor burred approximately
600 mm below ground and connected to earthing
electrodes driven in ground at certain intervals.

4. The soil resistivity of soil in switch yard should be

measured and soil strata should be considered to
design the earth mat.

5. The flow of ground fault currents in the earthing system

results into voltage gradients on earth surface in the
vicinity of grounding system.

6. All the equipments and their structures should be

earthed at two points and connected to earthing mesh.
 Fencing

Grounding strip should be run generally at 1 m distance

from out side the fence and the fence is connected to
earthing strip at corners and distance of 15 m. This is to
avoid the accidents to persons tuching the fence during
system fault conditions.

The cable tray brackets in cable trenches should be

earthed at some interval however the cable trays
should be earthed continuously.
 Control cable trenches and Control
cables

1. The control cable trench lay out is prepare as per

requirement / size of switch yard and number of bays
included in it. They run through switch yard to control
room

2. Generally a separate main cable trench runs through

the switch yard to control room for carring control
cables from various equipments in switch yard of 1
voltage level. i.e. in 132/33 KV two main control cable
trenches will run each from 132 and 33 kv switch yard.
Small cable trenches run from each equipment to main
cable trench.
3. The depth and width of cable trenches are decided on
number of cables required to be laid through the trench.

4. The slope is given to cable trenches towards lowest

portion of switch yard for draining rain water out of
switch yard.

5. The MS brackets (2 & 3 tier) are grouted along the wall

of the cable trench to run the cable trays on them.

6. The cable trenches are either of brick work or RCC.

7. The slabs are cast on these control cable trenches

where they cross the roads, so that cranes, trucks
carrying the heavy equipments can cross them.
8. The entry of cable trench in control room may be at one
place or number of places depending upon the lay out
of control and relay pannels in the control room.

9. The cable trays run on the MS brackets. The size and

number of cable trays depends upon number of cables
to be run on them.

10. The cable trench layout in control room is decided on

the basis of control and relay pannels layout in control
room.

11. In 400 KV sub station control and relay pannel rooms

are different and cable gallery is provided.
12. The control cable should be laid first on the cable trays
from the bottom tier. The care should be taken while
laying so that they are not damage during pulling from
cable drums.

13. The Al. tags showing the cable number purpose of

cable, from - to number of cores etc. should be tied on
each cable at both the ends as well at some interval for
cable identification.

14. The control cable are laid as per schedule prepared

earlier.

15. The control cables are taken in MBs, C & R pannels

and control cabinets of equipments by glanding.
16. The control cables are connected to the terminals after
crimping the lugs on the cores. Proper dressing of
cables and continuity of cables should be checked
before connections.

17. The control cables have very important role in

controlling the operations of vital equipments in switch
yards also in indication and annunciation systems and
hence should be properly handeled and connected as
said above.
 Control cable trenches and Control
cables

1. The control cable trench lay out is prepare as per

requirement / size of switch yard and number of bays
included in it. They run through switch yard to control
room

2. Generally a separate main cable trench runs through

the switch yard to control room for carring control
cables from various equipments in switch yard of 1
voltage level. i.e. in 132/33 KV two main control cable
trenches will run each from 132 and 33 kv switch yard.
Small cable trenches run from each equipment to main
cable trench.