Safe Operating Procedure

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Power Distribution Business Unit

Safe Operating Procedure
Document No. Rev :00 Date: Page 1 of 2
CONTENTS
Sl. No. Description Page No.
0 Revision Control Sheet 3
1 Abbreviation Sheet 4
2 Terms and Definitions 5-6
3 Tools and Equipment’s 7-15
4 Safe Operating Procedure for Pre Task Plan (PTP) 16-20
5 Safe Operating Procedure for Shutdown Procedure 21-31
6 Safe Operating Procedure for Survey 32-35
7 Safe Operating Procedure for Installation of Pole (Pole Shifting) 36-42
8 Safe Operating Procedure for Installation of Pole (Excavation for Pole Pit) 43-49
9 Safe Operating Procedure for Installation of Pole (Pole Erection) 50-57
10 Safe Operating Procedure for Structural Material Fitting 58-64
11 Safe Operating Procedure for Installation of Pole (Stay & Earthing) 65-70
12 Safe Operating Procedure for Stringing of Conductor upto 33 kV 71-98
13 Safe Operating Procedure for Installation of AB cable 79-94
14 Safe Operating Procedure for Under Ground Cabling 95-102
15 Safe Operating Procedure for Horizontal Directional Drilling (HDD) Work 103-109
16 Safe Operating Procedure for Installation of Distribution Transformer 110-115
17 Safe Operating Procedure for Service Connection, Meter Fixing &

116-120
Replacement of Meter
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18 Safe Operating Procedure for Repair and Maintenance Works 121-128
19 Safe Operating Procedure for Substation Civil Works 129-137
20 Safe Operating Procedure for Substation Mechanical Works

138-149
21 Safe Operating Procedure for Substation Testing & Commissioning 150-154
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BAJAJ ELECTRICALS LIMITED - POWER TRANSMISSION & DISTRIBUTION

Utility Power Distribution (UPD)
REVISION CONTROL SHEET
Rev. No. Date Reason for Revision Approved By
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ABBREVIATION SHEET
AB Cable Arial Bunch Cable
AB Switch Air Breaker Switch
ACSR Aluminum Conductor Steel Reinforced
BOCWA Building and other Construction Worker Act
CT/PT Current Transformer/Potential Transformer
DO Fuse Drop out fuse
DTR Distribution Transformer
EHS Environment Health & Safety
EHSM/EHSO EHS Manager/EHS Officer
EHV Extra High Voltage
FQAP Field Quality Assurance Plan
FRP/FGRP Fiber Reinforced Plastic /Fiber Glass Reinforced Plastic
GO Switch Gang Operated Switch
HV High Voltage
IE Rule Indian Electricity Rule
IR Insulation Resistance
LA Lighting Arrester
LOTO Lock Out Tag out
LV Low Voltage
MCB Miniature Circuit Breaker
MV Medium Voltage
P&M Plant & Machinery
PCC Pole Plain Cement Concrete Pole
PG Clamp Parallel Groove Clamp
PP Rope Poly Propylene Rope
PPE Personal Protective Equipment.
PTP Pre Task Plan
PTW Permit to Work
PVC Cable Poly Vinyl Chloride Cable
RCC Pole Reinforced Cement Concrete Pole
RCCB Residual Current Circuit Breaker
T&P Tools & Plants
UA/UC Unsafe Act/Unsafe Condition
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TERMS AND DEFINITIONS

Safe Operating Procedure (SOP): A Safe Work Procedure is a working risk control document
created by teams within the company that describes the safest and most efficient way to perform
a certain task. This document stays in the Health and Safety system for regular use as a template
or guide when completing that particular task on site. The document generally lists the associated
hazards involved in performing a task, what risk score is associated with the hazards (using a risk
matrix), what personal protective equipment is required, and the steps involved to complete the
activity without incident.
The document is split up to meet the above requirements as follows;

• Step
• Hazards
• Inherent risk
• Control measures
• Residual risk
Each person involved in that task on site must ensure all sections of the Safe Work Procedure
are followed. Safe Work Procedures are also required for machinery and equipment that is used
to perform activities. The procedures are required to be enforced within the workplace and
improved as conditions or equipment changes.
Battery Limit: A physical work zone identified at site for doing the shutdown activity. It includes
all equipment and associated components that act upon the primary electric supply for the system.
The battery limit is marked in PTP.
Authorized person: A person possessing adequate qualification, experience and skill for the
purposes of taking electrical shutdown activity. He should be capable to identify existing &
predictable hazards in system and has authority to eliminate it. The person should be permanent
employee and shall be authorized by Project manager.
Section In-charge: Shall have degree or diploma in respective discipline with min. of three years’
and experience in same kind of work.
Site Engineer / Qualified supervisor: degree or diploma in respective discipline minimum of one
year experience in same kind of work.
5
Sub-contractor Supervisor/ Gang Leader: A person nominated by sub-contractor for physical
monitoring of work activity carried by the workers. This person should be accepted by section in-
charge and trained on safety requirement.
(As per the Indian Electricity Rules, 1956)

“Low” where the voltage does not exceed 250 volts under normal conditions subject, however,
to the percentage variation allowed by these rules;
“Medium” where the voltage does not exceed 650 volts under normal conditions subject,
however, to the percentage variation allowed by these rules;
“High” where the voltage does not exceed 33,000 volts under normal conditions subject,
however, to the percentage variation allowed by these rules;
“Extra high” where the voltage exceeds 33,000 volts under normal conditions subject,
however, to the percentage variation allowed by these rules
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Safe Operating Procedure – Tools
& Equipment’s
TOOLS AND EQUIPMENT’S

Name Photo Safety Check
• The Safe Work Load (SWL) capacity of

PP Rope rope should be more than the tension
load.
• Ensure physical fitness of rope

• The SWL capacity of rope should be
Synthetic t Sling more than the tension load.
• Ensure inspection and color coding on
monthly basis
• Test certificate from competent person.

Wire Rope Sling more than the tension load.
monthly basis
• Test certificate from competent person

Pulley (Close) more than the tension load.
monthly basis

D Shackle more than the tension load.
monthly basis
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Lever Hoist (Pull lift) more than the tension load.
monthly basis
Chain Pulley Block • Ensure physical fitness of Chain Pulley

Block
more than the tension load.
monthly basis
Ratchet Leaching • Ensure physical fitness of webbing and

attachments
more than the tension load.
monthly basis
Crow Bar Insulated • Ensure physical condition

• Insulated for 11kV
Post Hole Digging Tool (Buggi) • Ensure physical condition

• Insulated for 11kV
• Ensure physical condition

Spade (Phawada) • Insulated for 11kV
Or Wooden Handhoe
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UG Cable detector Ensure good condition
FRP Ladder Ensure physical condition

Maintain ratio in 4:1 (vertical &
horizontal) and
Secure on top or hold by a worker on
ground
Carry inspection before use.
Bamboo Scissors • Ensure good physical

condition, Strong enough to take
load of 1Ton.
• Size 2.00 M & 4.5 M.
Skidder (Channel) • 100 mm channel

• 2 M. in length
Total Station Ensure calibration
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Theodolite & Staff Ensure good condition
Rodo Meter Ensure good condition
Measurement Tape
Ensure good condition
GPS with charger

Ensure good working condition
• Pre engagement inspection of equipment.

N.G. Hydra Crane Test certificate from competent person
Valid operator license.
• Guard for all rotating part.
• No hydraulic leakage.
• Monthly checking of crane as per the IMS
checklist
• Pre engagement inspection of equipment.

Mobile Crane Test certificate for competent person
• No hydraulic leakage
• Monthly checking of crane as per the
IMS checklist
• Pre engagement Inspection of equipment.

TMC Test certificate for competent person
• No hydraulic leakage
IMS checklist
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Truck • Valid operator license.
• Reverse horn
IMS checklist

HDD Machine • No hydraulic leakage.
• Earthing provided
• Good physical condition

• Maximum load capacity mentioned
Manual Trolley • Monthly inspection of the trolley
Good physical condition

Drum Jack Maximum load capacity mentioned
• Monthly inspection of jacks
• Test certificate for competent person
DG operated light mast • Good physical condition

• Monthly inspection of the light mast
trolley
• Earthing to the system
• RCCB fixed
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Pump for dewatering • Good physical condition
• Monthly inspection of the pump
• Guard for all retaining parts
Winch • Good physical condition

• Maximum load capacity mentioned
• Monthly inspection of jacks
• Test certificate for competent person
Guard for all retaining parts.
Distribution Transformer • Ensure required oil level

• No oil leakage
• No damage in insulator
AB Switch • No damage in insulator

• Ensure all required accessories are fitted
Lighting Arrestor Ensure good condition of

arrestor Ensure Megger Test
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AB Cable • Check the insulation resistance
• Ensure Megger Test
• No physical damage
Parallel Groove Clamp. Suitable for the fittings
1.5 M length (1.2 M

underground) Ensure 16
Spike Rod MM dia.
Discharge Rod • No physical damage

• Wire in a good condition
• No loose connection in lug
Pen Tester • Good working condition

• Ensure good condition of battery
DOLO Fuse • No damage in insulator

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Tirfor Ensure Third Party Inspection
Ensure no physical damage
Check mechanical grip
Continuity Tester • Good working condition

Discharge Rod • No physical damage

• Wire in a good condition
• No loose connection in lug
Pen Tester • Good working condition

DOLO Fuse • No damage in insulator

Tirfor Ensure Third Party Inspection

Ensure no physical damage
Check mechanical grip
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Continuity Tester • Good working condition
Torque Wrench • No physical damage

• Ensure calibration certificate
Tool Box Ensure availability of required tools in good

condition for the task
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Utility Power Distribution (UPD
Safe Operating Procedure : Pre Task Plan
1. PURPOSE
To provide documented procedure for preparing the Pre-Task Plan.
2. SCOPE
It covers the procedure for preparation of Pre Task Plan (PTP) for the activities as listed ow. The
PTP will be followed by BEL Employees, Subcontractors, Supervisors and Workmen working at
PT&D Site.
• Shutdown activity
• Pole and Transformer Erection nearby energized line
• Conducting and Dismantling existing structure nearby energized line
3. REFERENCE DOCUMENTS
3.1 Technical Specifications of Rural Electrification Corporation Limited (REC).
3.2 Approved Survey Drawings or Initial Detailed Survey drawings.
3.3 Contract Technical Specifications.
3.4 Client approved structural drawings, equipment drawings, earthing drawing
3.5 Electricity Act, 2003 and Electricity Rules, 2010
3.6 BEL EHS Manual
4. RESPONSIBILITY
4.1 Responsibility for preparation of this document lies with site qualified Supervisor
/ Site engineer (Nominated by PM/Site In-charge)
4.2 Evaluation and approval of this document lies with Section In-Charge and EHSO
4.3 Responsibility of implementation of this Procedure lies with Project Manager,
Section In-Charge, Site Engineer and Site supervisor of PT&D IC.
5. DEFINITIONS AND ABBREVIATIONS

5.1 Pre Task Plan: Pre-task plan (PTP) is a task planning process that identifies
hazards and provides a safe way of accomplishing that day’s tasks. PTP
identifies the following:
• The day’s work activities;
• Hazards associated with each work activity; and
• The steps employees will take to avoid the identified hazards.
If conditions change throughout the day, a new PTP must be completed. PTP gives each
employee a voice in creating the best and safest plan for completing his or her
assignments. It’s also a way for team members to take responsibility for their own safety
and for the safety of their fellow workers. Part of pre-task planning includes making sure
you have the right personal protective equipment (PPE) for the task.
6. EQUIPMENT AND ACCESSORIES
6.1 Measuring tape
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6.2 Rodo Meter (Measure distance & undulation)
6.3 Drawing Sheet (Blank)
6.4 Standard PTP format
7. PRE-REQUISITE / PRE-OPERATIONAL CHECK:
7.1 Wear required PPEs.

7.2 Collect the blank format and inspect physical site location to identify power
sources in the closed vicinity of working area.
7.2 Engage competent person for PTP work.
8. OPERATIONAL PROCEDURE:
8.1 Make Rough PTP from inputs of physical survey
8.2 PTP must be prepared minimum one day before executing the job
8.3 Prepare the Drawing (hand sketch) by marking North Mark, road map, clear land
mark, battery limit, work to be carried out, name of feeders and substation, EHV/
HT/ LT circuit crossings as per the ow mentioned list
8.4 Identify and record the physical hazards in access of work Location and work
areas.
8.5 Identify the number of Line Clearance (LCs) required (based on the following list)
8.4.1 All crossing lines within the Battery Limit (with identification).
8.4.2 Circuits running within 10 M vicinity of the working zone.
8.4.3 Composite / Multi Circuit pole in the battery limit
8.4.4 LT lines of other feeders in the battery limit
8.4.5 Street light circuit’s origin and timings of operation.
8.4.6 AB Cable (HT&LT) on the working pole
8.4.7 UG Cable connected to the circuit (if any)
8.6 Transmission line crossing – Verify the vertical clearance with the existing line
/new line by visual check if it is new line try to avoid mid span crossing. Minimum
Vertical clearance distance (in m) between lines when crossing each other is-
Sl. Nominal system 11-66 kV 110-132 kV 220 kV 400 kV 800 kV

voltage
1 Low and medium 2.44 3.05 4.58 5.49 7.94
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2 11-66 kV 2.44 3.05 4.58 5.49 7.94
3 110-132 kV 3.05 3.05 4.58 5.49 7.94
4 220 kV 4.58 4.58 4.58 5.49 7.94
5 400 kV 5.49 5.49 5.49 5.49 7.94
6 800 kV 7.94 7.94 7.94 7.94 7.94
(Ref IE Rule 1956, Rule 87)
1.1 Mark the Location of line isolation with clear land mark, battery limit and
grounding locations.
1.2 Climatic conditions to be recorded.
1.3 Identify number of intermediate Gang / Group Operating Switch (GOS) are within
the working zone in drawing.
1.4 Identify the number of jumpers and cut points in the work zone
1.5 Identify the possibility of back feeding from Generator (DG) / invertor (enquire
with local people and client official)
1.6 Identify existence of damaged pole/s in the working zone
1.7 Find out clearance between building’s staircase and line – to be identified, and
hazard found to be informed to the client for remedial measures including route
diversion.
1.8 Existing line details including originating and terminating end to be verified and
notified in the drawing (PTP).
1.9 Notify the location and number of poles to be dismantled.
1.10 Mention the locations, at where to provide earthing by discharge rod.
1.11 Individual Discharge Rods shall be used for Individual phases of the same line at
both side of battery limit.
1.12 Prepare the PTP by qualified site supervisor and site engineer
1.13 Get approval from Engineer & Section In-Charge / PM & cross check the same
by EHSO or authorized EHS representative.
1.14 Keep the PTP with Site engineer for ready reference at site, during execution.
1.15 Following symbol shall be use for preparing PTP
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Symbol Description Symbol Description
New PSCC Pole New HT Line

P
New Rail Pole Existing HT
R Line
New Steel New LT Line
S Tubular Pole
Existing Pole Existing LT Line
New Double Earthing

Pole (Discharge rod
location)
Existing Double Indication of

Pole Battery Limit
New DTR
Existing DTR
Jumper Opening
Jumper Closing
Four Pole
Structure
9. POST-OPERATIONAL CHECK
Section In charge shall check the following points.
9.1 Marked Battery Limit with available Land mark.
9.2 Mentioned LC detail requirement of available feeder where work to be executed.
9.3 Mentioned LC detail requirement of available additional feeder (If is Double
Circuit in which work to be executed.)
9.4 Mentioned LC detail requirement available of the other line, if the work zone.
9.5 Mark Pole condition, intermediate pole requirement and damaged pole
replacement location.
9.6 Pre-shut down check to be done from SS to work zone with induction tester by
putting the Racker (Circuit Breaker) at off & on at SS end for two to three times
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& feeling / ensuring that, the appropriate feeder is racked-out / isolated & correct
line is to be worked upon.
9.7 Used only identified symbols in the PTP format while preparing the PTP.
10. RECORDS AND CHECKLISTS

10.1 Approved Pre task plan (PTP)
10.2 Check list for Preparation of PTP
11. DISTRIBUTION
BEL- PT&D: Project Manager, Section-In-Charge / Site Engineer/Site Supervisors.
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Safe Operating Procedure: Shutdown Procedure
Document No. F 24 Rev :00 Date: Page 1 of 11
1. PURPOSE:
To provide documented operating procedure for shutdown activities to be executed in a
safe manner.
2. SCOPE:
It covers the work procedure of shutdown activity in utility power distribution projects, to
be followed by BEL Employees, Subcontractors, Supervisors and Workmen working at
PT&D Site.
3. REFERENCE DOCUMENTS:

3.2 Approved Survey Drawings or Initial detailed Survey drawings.
3.3 Approved Pre Task Plan (PTP)
3.4 Contract technical specifications.
3.5 Client approved structural drawings, Equipment drawings, Earthing drawing
3.6 Indian Electricity Rule 2005
3.7 BEL HSE Manual
3.8 Project EHS plan Emergency Response Plan (ERP)
4. RESPONSIBILITY:
Section In-Charge, Site Engineer and Site supervisor of BEL-PT&D IC.
4.2 Site EHSOs are responsible for cross checking the procedure implementation
4.3 Site Engineer / Section in-charge will get the critical activities (like Shutdown
jobs) physically cross verified the EHS Personnel prior to execution.
4.4 Supervisor will keep written record of all the above sequences executed as
evidence in the daily EHS Report format.
5. EQUIPMENT AND ACCESSORIES:
5.1 Electronic Multi Tester,

5.2 Discharged Rod,
5.3 HV Induction Tester,
5.4 Caution Board,
5.5 FRP ladder,
5.6 Spike rod
5.7 Red Flags, Barricading Tape
5.8 LOTO board,
5.9 GOS Lock & chain.
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5.10 Tokens
6. PERSONAL PROTECTIVE EQUIPMENTS&SAFETY GADGETS
Induction tester
Electrical rated Chain, Lock & Earth Resistance

hand gloves Discharge rod Spike Rod Danger Tag Key tester Token
7. PRE-REQUISITE /PRE OPERATIONAL CHECKS
7.1 Approved PTP

7.2 Availability of Screened, Inducted and trained workmen with required PPE
7.3 Visually inspect the required tools & ensure all in good condition and discard
defective tools.
7.4 Identify the approach road to the work location.
7.5 Identify a trained gang leader/ subcontractor supervisor to carry out the
shutdown process
7.6 Issue daily work permit to the subcontractor.
7.7 Shut down work permit
7.8 Pre-shut down check to be done from SS to work zone with induction tester by
putting the Racker (Circuit Breaker) at off & on at SS end for two to three times
8.1 Before getting permission from permit giving authority.
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8.1.1 Site Engineer / Section in-charge and sub-contractor supervisor/Gang
leader will read the approved PTP and understand the work
area/battery limits.
8.1.2 Supervisor and sub-contractor supervisor/Gang leader will do the walk
over survey with approved PTP.
8.1.3 Conduct Line verification to identify and prevent induction / back
feeding from other sources and understand the hazards noticed in the
PTP/involved other than that.
8.1.4 Communicate the LC program details minimum 24 hours before the day
of shutdown to Planning department, Section In charges and EHSO.
8.1.5 Ensure availability and use of induction testers, safety t, hand gloves
(Thermo-latex type and 11 kV & 33kV grade), spike rods, helmets,
Shorting clip, shoes, and FRP ladders.
8.1.6 Site Engineer / Section in-charge will get the critical activities (like
Shutdown jobs) physically cross verified the EHS Personnel prior to
execution.
8.1.7 Supervisor will keep written record of all the sequences executed as
evidence in the daily EHS Report format.
8.1.8 Obtain shut down by keeping Engineer at Sub-station & supervisor at
work location (Ref. Doc: LC Clearance permit)
8.2 After getting permission from electricity board.

8.2.1 Section In charge / Site Engineer will convey the LC line details to site
supervisor through mobile SMS with copy marked to PM. (Though both
of them are nearby / together) The content of SMS shall have minimum
information as mentioned ow.
8.2.2 Section In charge / Site Engineer will obtain special permission from
PM if lineman is not available from client end to ensure the PM aware
of number of locations where the isolation (Jumper Removal) is to be
done by our workmen.
8.2.3 PM & Section In-charge Keeps records of information of how many &
which locations our workers are engaged in isolation process (Jumper
Removal).
8.2.4 Section In-charge / Site Engineer will Cross check & Front Line
Supervisor will ensure availability, working condition & effective usage
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of Safety gadgets & PPEs (Helmet mounted Induction tester, HV
Testers, Discharge Rods, safety shoes, safety harness and thermo-
latex hand gloves etc.) prior to initiate the activity.
8.2.5 Conduct PEP talk to sensitize & let follow procedure through Tool Box
talk before starting of work
(Brief the battery limit area to workmen in particular along with Do’s & Don’ts of
the Activity)
8.2.6 Communicate Emergency Response Plan including rescue operations,

First aid and Nearby Hospital details in understandable language.
8.2.7 Issue blue token for workers to work at ground level for the
preparedness of LC jobs after receiving the SMS (as per 8.2.1) from
the Site Engineer
8.2.8 Check the line with Pen type induction tester / Helmet Mounted
Induction Tester (HMIT) / HV tester and ensure there is no power
supply / back feed in the line & communicate the findings to Engineer
8.2.9 Cross verify the isolation point as per PTP.

8.2.10 Check all spike rod resistance and ensure that it is less than 10 ohms.
Install the spike rod up to the mark of penetration in earth
8.2.11 Use nut & bolts to loop all spike rods for shorting (Minimum dia. of MS
spike rod is 16 mm and depth inserted into ground upto 1200mm)
8.2.12 Connect discharge rod wires to the spike rods by using the nut & bolt
and tight properly.
8.2.13 Pour saline water over the spike rod in case the resistance is high
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8.2.14 Use 11kV hand gloves, keep the conductor of discharge rod away from
body while placing the discharge rod in position with the conductor
8.2.15 Place the first discharge rod along with HV Tester initially (One
Discharge rod fitted with HV Detector per set of 6 or 8 Discharge rods)
8.2.16 Check for any sparks, buzzer/alarm of the HV Tester while connecting
the first discharge rod. After confirming no Sparks, position the rest
discharge rods
8.2.17 If any induction / back feed sources found, then arrange shutdown for
crossing lines and disconnection of back feed lines.
8.2.18 Ensure the Positioning of discharge rods before & after the jumper for
all the conductor phases.
8.2.19 Use individual discharge rod with spike rod to ground each conductor
& connect / short the spike rods & tight properly with nuts & bolts.
8.2.20 Supervisor sends SMS to the Site engineer by having minimum

information as mentioned ow & convey same through phone call.
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8.2.21 Engineer will reply to the SMS of supervisor by giving approval to issue
Red Token & Work Permit.
8.2.22 Supervisor requests line man from client end to remove jumper from
the specified isolation point
(If line man Available)
8.2.23 Supervisor will issue LC token (Red Token & Supervisor to WM Permit)
to the workman who is / are about to remove jumper after receiving
reply from the site engineer as approval.
8.2.24 Workman who is to climb the pole must wear Helmet mounted Induction
tester, safety shoes, safety harness and thermo-latex hand gloves and
have the token displayed tied on his arm.
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8.2.25 Do not remove Helmet mounted induction tester until completion of
work
8.2.26 Use FRP ladder to climb on the pole and Full body Harness (Sit and
Stand Type / R-APDRP Type) while working in the pole.
8.2.27 Remove the jumper & isolate the line to work.

8.2.28 Open the GOS wherever option is available with 11 kV or 33 kV
electrical hand gloves and provide
Lock with Caution tag (Men at work, Do not Operate) and deploy a watchman. (where applicable)
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8.2.29 Supervisor issues LC token (Red Token & Supervisor to WM Permit) to
other workers who work at height.
8.2.30 After removal of jumper from the isolation point / GOS Isolation, Check
the line with Pen type induction tester / Helmet Mounted Induction
Tester (HMIT) / HV tester and ensure there is no power supply / back
feed in the line & communicate the findings to Engineer
8.2.31 If any induction / back feed sources found, then arrange shutdown for
crossing lines and disconnection of back feed lines.
8.2.32 Relocate the discharge rods to the work zone and position them at both
the ends of work zone to make a safe battery limit.
8.2.33 Remove all possible jumpers to isolate the work location from every
end within the vicinity area of work zone and short the Aluminium
conductor steel-reinforced (ACSR) conductor even if the line is a newly
constructed one by checking with Pen type induction tester / Helmet
Mounted Induction Tester (HMIT) / HV tester.
8.2.34 Supervisor cross verifies the battery limit is safe to work & issues permit
(Supervisor to WM Permit) to the rest worker(s) are about to climb on
pole(s)
8.2.35 Do not leave any hand tools or personal ongings on the pole after
completion of work.
8.2.36 Work within Battery Limit
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8.2.37 Supervisor ensures his presence throughout the activity to monitor
effectively so that no workman / workmen are working outside the
battery limit area
8.2.38 Site Engineer have to do cross check periodically by calling the
supervisor to monitor whether workers are working within BL.
8.3 LC can be availed in the following forms

8.3.1 Full feeder LC
8.3.2 GOS opening for the work zone
8.3.3 Removal of Jumper for the work Zone under shut down of feeder
8.3.4 In case to execute one LC program by deploying workmen in more than one
places / gang
a. Do not issue One LC number to multiple working gangs
b. Site engineer will make and issue independent LC numbers to each of
the gang.
c. Return the LC to client authority by site engineer only after ensuring the
all ‘Gang LC’s
are being returned from the Supervisors of each gang.
8.4 After work completion:

8.5.1 Supervisor has to Check for Work completion [Ref. Doc.: Checklist and return
permit to work]
8.5.2 Check the line with Pen type induction tester / Helmet Mounted Induction Tester
(HMIT) / HV tester and ensure there is no power supply / back feed in the line
& communicate the findings to Engineer
8.5.3 Install the spike rod and Discharge rod at both the sides of pole where jumpers
to be connected back.
8.5.4 Request the Line man or Engage our workmen (only if required) to re-connect
the Jumpers.
8.5.5 Collect back the Red Tokens from the workman/ workmen.
8.5.6 Do not collect the token if a workmen returning the token of the other, Ensure
every worker must return his token to the supervisor individually.
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8.5.7 Close GOS wherever it was open
8.5.8 Remove all shorting of HT/LT lines

8.5.9 Remove all discharge rods from HT/LT lines.
8.5.10 While removing the discharge rod, disconnect the rod first, and then remove the
connection from earth spike.
8.5.11 Remove LOTO Tag placed near Gang Operated Switch / AB switch etc.
8.5.12 Ensure that all tools and tackles have been removed from Work Location.
8.5.13 Collect the Blue token & Ensure every workmen is out of the work zone.
8.5.14 Follow Check List for Shut Down Activity

8.5.15 before withdraw of Line Clearance
8.5 RETURNING THE LC

8.5.1 Inform all workmen regarding the closure of LC.
8.5.2 Supervisor will send an SMS to Site engineer informing the closure of work and
returning of Line Clearance & also by calling in phone
8.5.3 Return LC permit to the concerned State electricity board authority / Issuing
authority by Site Engineer mentioning that all activities have been completed
and Signature acknowledgement with stamp of issuing authority taken in the
LC permit format. [Shut Down Clearance (HT / LT) cum Work Permit for
Transmission Line, APDRP / Rural Electrification and other Works
8.5.4 Charge the Line and check with induction tester to confirm
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8.6 Token System
8.6.1 Token system must consist of four colours which shall be followed as per the table
given ow.
8.6.2 Supervisor will issue Yellow tokens to ground working workmen in case of no
line clearance is planned.
8.6.3 Supervisor will issue green token, during height work in case of no line
clearance is planned to required fitters.
Non LC LC
Ground Yellow Blue
Height Green Red
8.6.4 Supervisor will issue Blue token to all workmen prior to the LC work on the day.
8.6.5 Supervisor will issue red tokens only after taking Line clearance permit from client
and receiving SMS as order/permission from the concerned engineer.
9. POST OPERATIONAL CHECK

9.1 Inform regarding closure of line clearance to all workmen and shift the gangs
from Battery
limit.
9.2 Ensure that the power has been restored successfully.
10. RECORDS
10.1 Approved PTP
10.2 Line Clearance checklist cum LC Permit
10.3 Shut Down Clearance (HT / LT) cum Work Permit for Transmission Line,
APDRP / Rural Electrification and other Works
10.4 Check List for Shut Down Activity
10.5 Pep talk report (
10.6 Emergency Response Plan (ERP) (if Required)
11. DISTRIBUTION
BEL: PT&D -> Project Manager (PT&D), Section-In-Charge / Site Engineer/Site Supervisors
31
f

Safe Operating Procedure: Survey
1. PURPOSE:
To provide documented operating procedure for survey activities in utility power
distribution projects to be executed in a safe manner.
2. SCOPE:
It covers the safe work procedure of surveying activity of new and existing route for HT/
LT line including Digital Transformer Ratiometer (DTR) location (existing and proposed)
in UPD projects, to be followed by BEL Employees, Subcontractors, Supervisors and
Workmen working at PT&D Site. The activity wise SOP bifurcation is given ow.
Activity Sub-Activity Geographical Profile Customer Needs
Survey Plain land
Manual Survey Hilly area
GPS SURVEY Forest area
Riverine Area
Desert area
3.1 Project EHS plan

3.2 Tender Specifications and detailed project report
3.3 Client existing layout if any
4. RESPONSIBILITY:
4.1 Responsibility of implementation of this Procedure lies on Project Manager,

Section in-Charge, Site engineer, Site qualified field supervisor of PT&D IC.
4.2 Responsibility of cross checking lies on Site EHSO/EHSM

5.1 Total Station
5.2 Theodolite
5.3 Road meter
5.4 Measurement Tape
5.5 GPRS with charger
32
6. PERSONAL PROTECTIVE EQUIPMENTS AND SAFETY GADGETS:
Thermo-latex hand Safety Appropriate

Gloves Goggles Footwear Multi Tester Reflective Jacket
7. PRE-REQUISITE/PRE OPERATIONAL CHECK:

7.1 Ensure the availability of qualified supervisor/ surveyor/ Engineer for survey
activity
7.2 Check required tools for survey and must be in good condition
7.3 Ensure the availability of Required PPEs
7.4 Ensure the availability of required permits to enter in restricted areas
7.5 Check availability of list of sub-station/feeders from tender documents
7.6 Schedule Survey works program from the clients
7.7 Keep an effective communication system (mobile, walky-talky etc.). If required,
whistles can also be used in closed network.
7.8 Ensure the availability of Emergency Rescue arrangement
7.9 Ensure availability of First Aid Box with medicines.
7.10 Carry sufficient dry food & water
7.11 Follow shutdown procedure, if shutdown required.
7.12 Verify the validity of Driving License
8.1 Plain Area:

8.1.1 Assess the area where to conduct survey, locality and route.
8.1.2 Decide mode of transport to be used.
8.1.3 Deploy experienced staffs.
8.1.4 Take help of local enforcement authority to enter the area, if any local issue
exists.
8.1.5 Use proper PPEs, i.e. gum boot/ High ankle shoe, safety helmet, reflective
jacket
8.1.6 Take care for HT/LT/hooking line during survey work especially during
handling of level staff and ranging rods.
8.1.7 Keep close look all around you for possibility of any vehicle movement. If
required, barricade the area with cone and warning barricade
8.1.8 Be aware of Wild / Ferocious animal and insects/reptiles exist around the
area.
33
8.1.9 Complete the work during day time especially under clear sunlight visibility.
8.1.10 Avoid using steep sloped pathway and select an alternative way;
8.1.11 If possible wear protective clothing to protect from any insect attack/ hot sun
8.1.12 Check local medical centre where anti-venom is available in case of
emergency
8.1.13 Carry umbrella with wooden handle /rain coat to protect from sun/rain
8.1.14 Do not take any short cut route / method
8.1.15 In case of crossing railway tract/Road follow the signal.
8.1.16 Use Crash Helmet for bike riding
8.2 Riverine Area:

8.2.1 If provision of crossing of river/lake/canal through bridge, then follow that
route only
8.2.2 If crossing of river is required, be careful about the water current. Engage
boats for crossing if required. Use life jacket for all persons on boat
8.2.3 If survey is required in water logged area, use a stick to assess depth of the
water. Do not move forward if depth is more than 1 m.
8.2.4 Restrict line working in case of water logged area
8.3 Forest area:

8.3.1 Do not enter into a forest without the knowledge of forest Department.
8.3.2 Follow the instruction of the forest official who comes along with the gang.
8.3.3 Use binocular for finding out any wild animal/ undulating profile along the
survey route 8.3.4 Use closed vehicles for safeguarding from freely
flying insects and also from wild animals.
8.3.5 Carry carbolic acid.
8.3.6 Keep markers along the way indicating the route taken?
8.3.7 Use high ankle boot & full sleeve cloths to prevent insect bite.
8.4 In Hilly Terrains:

8.4.1 Don’t take risk if suspects any free boulder/land slide
8.4.2 If any boulder rolling through the mountain, wait until it clears the path;
8.4.3 Avoid using steep sloped pathway and select an alternative way;
8.4.4 Use mountain climbing shoes
8.4.5 Carry carbolic acid
8.4.6 Don’t use tree as a support without assessing its stability.
8.4.7 Persons with chronic Heart Diseases / high Blood pressure must be avoided.
8.4.8 Use full sleeve cloths to prevent insect bite.
8.5 Desert Area

8.5.1 Cover the body and face. Use goggles.
8.5.2 Use four-wheel drive vehicles which are, fitted with radial type of tyres.
34
8.5.3 Preparer for emergency & Check local medical centre where anti-venom is
available in case required.
8.5.4 Use high ankle boot & full sleeve cloths to prevent insect bite.
8.6 Make rough PTP after the survey for further reference.
8.7 Pre-shut down check to be done from SS to work zone with induction tester
by putting the Racker (Circuit Breaker) at off & on at SS end for two to three times

9.1 All the survey crew should assemble in one predefined place after completion
of survey
9.2 Check instrument taken for survey is brought back and also check physical
condition for proceeding to further assignment
10. RECORD
Permit to work for restricted area if required
11. DISTRIBUITION
BEL-PT&D: Project Manager (PT&D), Section-In-Charge / Site Engineer/Site
Supervisors/Surveyor
35
f

Safe Operating Procedure: Installation of Pole (Pole
Shifting)
1. PURPOSE:
To provide documented operating procedure for shifting of poles in a safe manner.
2. SCOPE:
It covers the safe operating procedure for the activity in UPD, to be followed by BEL
Employees, Subcontractors, Supervisors and Workmen working at PT&D Site. Pole
erection activity can be sub divided into following activities 2.1 Manual shifting of pole in
plain land.
2.2 Manual shifting of pole in hilly area.
2.3 Manual shifting of pole by boat
2.4 Mechanical shifting of pole
3.1 Approved Survey Drawings
3.2 Approved Pre Task Plan
3.3 Approved Safety Shutdown Procedure
3.4 Final Test Pit data of the route.
3.5 Approved EHS Plan,
3.6 Project Quality Plan, and Field Quality Assurance Plan (FQAP)
3.7 Climate information from meteorological department.
4. RESPONSIBILITY:
Section In-Charge, Site engineer, Site qualified field supervisor, identified and
trained gang leader of subcontractor of PT&D IC.
5.1 Manual Shifting

5.1.1 Hand cart
5.1.2 Crowbar
5.1.3 PP Rope.
5.1.4 Red Flags
5.2 Mechanical Shifting

5.2.1 Truck Mounted Crane (TMC)
5.2.2 New Generation Hydra crane
36
5.2.3 Trailer
5.2.4 Lifting sling (2 Ton, 6 M)
5.2.5 D- shackles
5.2.6 PP Rope / Ratchet Tie
6. PERSONAL PROTECTIVE EQUIPMENTS
Induction
tester
Fall arrester
with Life line
1. PRE-REQUISITE/ PRE OPERATIONAL CHECK
1.1 Visually inspect the required tools for shifting work and ensure all in good
condition and discard the defective tools.
1.2 Inspect the hand cart and ensure good condition of structure and tyre pressure.
1.3 Ensure Fitness inspection of TMC / Crane/ Trailer and Test certificate from
competent person.
1.4 Ensure Third party test certificate for all lifting tools.
1.5 Ensure Valid Driver License and Pollution Under Control (PUC) certificate
1.6 Allow only screened and Safety Inducted workmen for work.
1.7 Ensure number of manpower as per the pole weight (per person 30kg) is
available with gang.
37
1.8 Ensure required PPE is available with all workers.
1.9 Obtain required permits for movement and shutdown if required.
1.10 Identify the approach road and unloading point of the pole
1.11 Engage a trained gang leader/ subcontractor supervisor to carry out shifting in
his physical presence.
2.1 Manual shifting of pole in plain land

2.1.1 Spread bleaching powder over the stacked pole, and allow sometime so that
snake and other insects come out from pole stack.
2.1.2 Check the pole whether any crack developed or not. Spread water on the
poles to find hair crack on it or Strike with wooden 5 pound hammer for sound
checking of damage identification of pole. Check RS Joist pole for any bend,
identify double pole, four pole as per drawing.
2.1.3 Provide wooden packing under the pole while lifting the pole to avoid
pressing of fingers in between pole and fingers.
2.1.4 Lift one end of pole up to the tyre level of hand cart, then place the pole on
the bed of hand cart.
2.1.5 Provide wooden block/brick under the tyre of Hand cart to restrict its
movement during loading.
38
2.1.6 Avoid shifting of other loose materials along with pole.
2.1.7 Do not keep the people in front of vehicle during shifting of pole in slope area.
Use rope from back side and slow down the vehicle.
2.1.8 Deploy Minimum 2 trained signalmen with red and green flag and whistle in
front and back of pole to control the traffic.
2.1.9 Exert the force at the time by all gang members. Maintain group coordination
/ understanding among the gang members.
39
2.1.10 Tie the pole rigidly with hand cart by means of rope, in three places before
start moving the trolley.
2.1.11 Do not carry shifting work at night.
2.1.12 Move slowly during manual shifting (Max walking speed 3km/hr.)
2.1.13 Do not carry more than two poles (8 M) on one trolley at a time.
2.2 Manual shifting of pole in Hilly land

2.2.1 Restrict the manual trolley for slope more than 15 degree.
2.2.2 Shift pole manually on hill by lifting on shoulder with the help of PP rope and
50 mm MS pipe/ wood log (minimum 60 mm).
2.2.3 Ensure number of manpower as per the pole weight (per person 30 kg) is
2.2.4 Ensure the usage of shoulder pad to protect shoulder.
2.3 Pole shifting by Mechanical method.

2.3.1 Check the condition of access of transport and location of the unloading.
2.3.2 Ensure Loading and Unloading ground points are levelled.
2.3.3 Ensure pole is shifted only on a TMC, long bed truck or double shaft trailer.
(Do not use Single shaft trolley for pole shifting) Check outriggers of TMC
must be fully extended during loading and unloading of the material.
2.3.4 Combined weight of poles that are being shifted must not exceed 1.5 Ton
(with the Sling capacity of 2 Ton)
2.3.5 The Combined weight of poles lifted together must be less than the SWL
(Safe Work Load) of the crane.
2.3.6 Use tag rope for controlling the movement of pole while lifting.
2.3.7 Do not exceed the projection length of the pole more than the 1/3 of the pole
during shifting.
2.3.8 Provide red flag/warning reflective triangle at the projection end of pole.
40
2.3.9 Do not shift pole by dragging on road / Hard surfaces
2.3.10 Tie the pole rigidly with Trailer by means of ratchet t / rope sling.
2.3.11 Do not be in over speed during shifting by Trailer, follow the maximum speed
limit 40 KMPH on high way and 25 KMPH in rural road.
2.3.12 Deploy one signal man with flag and whistle at the rear end of trailer while
reversing
2.3.13 Don’t allow worker on trailer along with the Pole and other material.
2.3.14 Cordon all the unload area and do not allow any person under hanging load.
2.4 Pole shifting by boat (river crossing/ water log area):

2.4.1 Assess the carrying capacity of the boat and define the number of poles can
be carried in one time.
2.4.2 Minimize the number of person travelling along with pole on boat.
2.4.3 Don’t allow local public to travel along with the pole on boat.
2.4.4 Check the condition of boat and ensure that the boat is in good condition to
carry the pole.
2.4.5 Do not shift pole by boat during inclined weather condition or in night.
2.4.6 All workers over boat should wear life jacket
2.4.7 For loading the pole on boat the lift the pole by carrying on shoulder with the
help of PP rope and 50 mm MS pipe/ wood log (minimum 60 mm).
2.4.8 Ensure number of manpower as per the pole weight is available with gang.
41
3.1 Re instating all disturbed public utilities.
3.2 Ensure positioning of pole on even surface after shifting.
3.3 Ensure the packing ow the pole while stacking
3.4 Ensure the pole stack is not obstructing the traffic and free movement of people.
4. RECORD
4.1 PEP talk
4.2 Daily work Permit.
4.3 Shut Down / Line Clearance Permit – if required
4.4 Checklist for shutdown – if required
5. DISTRIBUITION
Supervisors
42
f

Safe Operating Procedure: Installation of
Pole (Excavation for Pole Pit)
1. PURPOSE:
This is to provide documented operating procedure for executing the Excavation for Pole
Pit activity in a safe manner.
2. SCOPE:
It covers the safe operating procedure for Pit Excavation activity and related sub activities
as mentioned ow, to be followed by Employees, Subcontractors, Supervisors and
Workmen working at PT&D Sites:
Process Geographical Customer Needs

Variety
Mechanical Plain land PSCC (Pre stressed Cement Concrete) Pole
Manual Hilly area PCC (Plain Cement Concrete) Pole
Forest area RCC (Reinforced Cement Concrete)
Pole
Riverine Spun Pole
Area
Desert area ST Pole
RSJ (Rolled Steel Joist Pole)Type Pole
Rail Pole
3.1 Technical Specifications and Rural Electrification Corporation Limited (REC)
guidelines.
3.2 Building and Other Construction Workers Act, 1996
3.3 Approved Survey Drawings and Final Test Pit data of the route.
3.4 Underground Utility network detail given by local administration
3.8 Approved Pre Shutdown Survey if required
3.9 Excavation clearance permit
3.10 Climate information from meteorological department.
3.11 Approved emergency response plan
3.12 Quality Management System Manual, and Field Quality Assurance
Plan (FQAP)
43
4. RESPONSIBILITY:
Section In Charge, Site engineer, Site qualified field supervisor, identified and
trained gang leader of subcontractors of PT&D IC.

5.1 Spade with wooden handle
5.2 Crow bar with insulation cover (as per the requirement)
5.3 Mechanical / Motorized auger with insulated handle (as per the requirement)
5.4 Bucket / De-watering Pump (as per the requirement)
5.5 UG cable indicator (as per the requirement)
6. PERSONAL PROTECTIVE EQUIPMENTS
Helmet With
Induction
Sensor Induction tester
Fall arrester
with Life line
7. PRE-REQUISITE/PRE OPERATIONAL CHECK
7.1 Approved Pre Task plan shall be available at location.

7.2 Take shut down for nearby overhead (if required) and underground utility. 7.3
Approved Survey Drawing shall be available at the location
7.4 Obtain all work permits before starting of work.
7.5 Ensure the availability of Location specific emergency plan to the crew leader,
frontline supervisor and the engineer in charge.
7.6 Ensure the availability of Approved FQAP and Checklist of the procedure with
crew leader, frontline supervisor and the engineer in charge.
44
7.7 Ensure that the only screened and trained workmen are involved for the work 7.8
Engage trained subcontractor (s/c) supervisor for monitoring the excavation
work.
7.9 Ensure insulated shovel must be used for pit excavation work.
7.10 Do Visual inspection of required tools for shifting work and ensure all in good
condition and discard defective tools.
7.11 Issue daily work permit to the subcontractor
7.12 Ensure required PPEs should available with all workers.
7.13 Take required permits for movement and shutdown if required.
7.14 Identify the approach road, underground utility and nearby structure unloading
point of the pole.
7.15 Conduct PEP talk with DO’s and Don’ts before starting of activity.
8.1 Identify the type of soil and the ground water level before commencing
excavation at place where excavation to be made.
8.2 Use dewatering pump / bucket In case of presence of ground water at the level
of excavation for dewatering purpose
8.3 Collect complete information on the underground structures (Such as Water
pipelines, sewers, gas mains, electrical conduit systems and other civic
facilities) from local authority before doing the excavation work.
8.4 Use cable detector, to check the Existence of underground utility.
8.5 Obtain Excavation clearance permit from concerned authority if underground
facilities exist or the excavation is done in the proximity of a structure
8.6 Take permit from concerned authority In case of existence of underground
installations such as Electrical Cable, Gas Pipe Line, and Water/Sewage Pipe
Line etc. for its isolation.
45
8.7
Use Only insulated tools like insulated shovels, wooden handle spade,
insulated Crow Bar, wooden handle pickaxe etc.) for pit excavation.
8.8 Depth of pole pit shall be based on pole type and pole length (refer approved
drawings
8.9 Insulated crow bar
8.10 Ensure step cutting for easy access and lifting of pole during erection. First step
on one meter and second step on 2 feet or as per the drawing. Ensure slope on
one side of pole pit area where pole has to be erect in case of RS Joist pole
erection.
Slope provided
8.11 Stack the excavated soil at least 1.5 meters away from edge of excavated pit or
half of the depth of the pit whichever is more.
8.12 Ensure barricade provided and warning signs displayed so that unauthorized
entry is restricted specially while working near busy roads & highways.
46
8.13 Use de-watering pump / Bucket, if there is any source of seepage water to avoid
soil collapse.
8.14 Do not carry any vertical cut to avoid soil collapse.
8.15 Do not carry any under cutting which may lead collapse of side wall.
8.16 Do not use any type of metal rings, gold / silver chains (Neck) or any loose
clothing during site work.
47
8.17 Do not allow Single worker for pit excavation activity. Ensure two workers shall
be engaged for pit excavation work.
8.18 Ensure proper use of PPEs like safety helmet, reflective jackets, hand gloves,
safety shoes, and Gum boots.
8.19 Ensure hard barricading of Excavated area with warning sign if pole erection is
not completed on the same time or day. Never leave excavated pit without
providing barricade or hard covering
Warning barricading net used for

pit barricading
9. POST OPERATION CHECK

Ensure all the left out pit should be barricaded or covered at the end of the day
work
48
10.1 Pre task Plan
10.2 PEP talk
10.4 Shut down document if taken
10.5 Excavation clearance permit if required
11. DISTRIBUITION
BEL-PT&D: Project Manager (PT&D), Section-In-Charge / Site Engineer/Site Supervisors
49
f

Pole (Pole Erection)
1. PURPOSE:
To provide documented operating procedure for Pole erection activities to be executed
in a safe manner.
2. SCOPE:
It covers the work procedure of Pole erection activity in UPD projects, to be followed by
BEL Employees, Subcontractors, Supervisors and Workmen working at PT&D Site.
Process Geographical Variety Customer Needs

Mechanical Plain land PSCC (Pre stressed Cement Concrete) Pole
Manual Hilly area PCC (Plain Cement Concrete) Pole PCC Pole
Forest area RCC (Reinforced Cement Concrete) Pole

Riverine Area Spun Pole
Desert area ST Pole
RSJ (Rolled Steel Joist Pole)Type Pole
Rail Pole
3.1 Technical Specifications of Rural Electrification Corporation Limited (REC)
3.2 Approved Vendor Drawings
3.5 Approved Pre Shutdown Survey (if required )
3.7 3.7 Final Test Pit data of the route.
3.8 Approved EHS plan
4. RESPONSIBILITY:

Section In-Charge, Site Engineer and Site Qualified field supervisor of PT&D IC.
4.2 Site EHSOs are responsible for cross checking the procedure implementation

5.1 Hand cart
5.2 Insulated Crowbar
5.3 PP Rope (20 mm / 25mm).
50
5.4 Skidder
5.5 Bamboo Scissors (Kainchy)
6. PERSONAL PROTECTIVE EQUIPMENTS AND SAFETY GADGETS
7.1 Allow workers with height pass only to work on top of the pole.
7.2 Ensure safe work procedure of shutdown activity if there is any existing line
before pole erection activity.
7.3 Visually inspect the required tools for shifting work and ensure all in good
condition and discard the defective tools.
7.4 Inspect the hand cart and ensure good condition of structure and tyre pressure.
7.5 Ensure Fitness inspection of TMC/Crane/Trailer and Test certificate from
competent person.
7.6 Ensure Third party test certificate for all lifting tools.
7.7 Ensure Valid Driver License and Pollution Under Control (PUC) certificate
7.8 Allow screened and Safety Inducted workmen only for work.
7.9 Ensure number of manpower as per the pole weight (per person 30 kg) is
7.10 Ensure required PPE is available with all workers.
7.11 Obtain required permits for movement and shutdown if required.
7.12 Identify the approach road and unloading point of the pole
7.13 Identify a trained gang leader/ subcontractor supervisor to carry out shifting in his
physical presence.
7.14 Conduct Pep talk with DO’s and Don’ts before starting of activity.
51
8.1 During Shifting of Pole / RS Joist pole:

8.1.1 Check the pole physically to identify any bend.
8.1.1.a Visual checking method
8.1.1.b Identify double pole, four pole as per drawing
8.1.2 Check the depth of Pole pit as per specification and approved drawing
8.1.3 Take traffic clearance and ensure the work area is barricaded with Safety
cone, safety caution boards and Barricading tape.
8.1.4 Ensure the availability of required manpower.(Ref Table ow)
Pole type RS Joist pole Number workmen required

PSCC 8 M – 425 Kg (Max) RSJ 11M- 400 Kg (Max) 11
PSCC 9 M –695 Kg (Max) RSJ 13M- 500 Kg (Max) 14
STP 9 M (SP-33) -175 Kg (Max) 8
STP 11 M (SP-55) – 240 Kg (Max) 8
STP 13 M (SP-72) – 360 Kg (Max) 10
8.1.5 Ensure step cut being done in the pole pit excavation / ensure slope on
one side of pole pit area where pole has to be erect in case of RS Joist
pole erection.
8.1.6 Depth of pole pit varies based on Pole type and pole length (Please refer
respective approved drawings for Pit size)
8.1.7 Place the Skidder (Channel) inside of the pit, at opposite side from where
the Pole to be erected.
52
8.1.8 Positioning and lowering of hand cart shall be done near excavated pit
to let the pole touch the skidder and stop the movement of trolley by
scotch block.
8.1.9 Make boundary around the pit by mud for enabling de – watering in case
of working in mercy land.
8.1.10 Do dewatering by the use of bucket.
8.1.11 Nobody should stand / sit beside deep trench during working in hilly
terrain.
8.1.12 Avoid steep slope of hilly terrain during identification of location of Pole
erection point.
8.1.13 Bracket should be fitted with the pole if supply of accessories is available
at the time of erection.
8.1.14 Fix the 4 Nos. guy ropes at the top of the pole
8.1.15 For 11 / 13 M Pole place another 2 Nos. of PP Rope at hip position of
the pole
8.1.16 Hang the slabs / stone pad by putting the slabs / stone pad in the middle
of two PP ropes kept hold by two workmen.
8.1.17 Down the slabs / stone pad inside of the pit.
8.1.18 Check the skidder, whether it is firmly placed or not.
53
8.1.19 Place the guy pins firmly with 2/3rd of crow bar under the ground at four
sides of the Pole, at an angle of less than 45 degree at a min distance of
15 M.
8.2 DURING POLE ERECTION ACTIVITY:

8.2.1 Fix the 4 Nos. guy ropes at the top of the pole
8.2.2 For 11M Pole place another 2 Nos. of PP Rope at hip position of the pole
8.2.3 Bracket should be fitted with the pole if supply of accessories is available
at the time of erection
8.2.4 Place the guy pins firmly with 2/3rd of crow bar under the ground at four
sides of the Pole, at an angle of less than 45 degree at a min distance of
15 m.
8.2.5 Push the hand cart towards the pit and make it touches the skidder by
lowering the hand cart.
8.2.6 Stop the movement of trolley by using scotch block.
8.2.1 Nobody shall stand on the pole end as dead weight.
8.2.2 Place the Kainchy (Bamboo Scissor) at the other end (top) of the pole.
8.2.3 Lift the Pole slowly manually and make it rested on Kainchy.
54
8.2.4 Remove away the hand cart to the opposite side of pit at a safe distance
of min 10M so that it does not create obstruction for erection process.
8.2.5 Now gradually lift the Pole manually and with the help of Kainchy and tie
the other guy ropes with the anchor (Guy Pin).
8.2.6 Place the pole on concrete slab / stone pad and check the alignment with
the help of plumb bob.
8.2.7 Complete shuttering and concreting activity in pit as per specification.
8.2.8 Backfill the pit with sand and bricks or with soil or with concrete as per
specification.
8.2.9 Compaction to be done with the help of rammer.
8.2.10 Remove the guy rope from anchorage, at least after 2 hours of
concreting.
8.2.11 Ensure that no one shall come in the vicinity of pole (to avoid accident in
case of breaking of guy rope.
8.2.12 Place the ladder against the pole for safe access to top of the pole.
8.2.13 Wear the full body harness.
8.2.14 Deploy one man to hold the ladder firmly on ground.
55
8.2.15 Anchor safety harness with pole and waist t to be tied with pole after
reaching at top rung of ladder then remove guy rope.
8.3 For installation of Rail Pole by using Tirfor
8.3.1 Select Tirfor of adequate capacity to erect rail pole 8.3.2 Check
the Test certificate of Tirfor 8.3.3 Drive anchor for fixing Tirfor.
8.3.4 Drive guy pin at 4 side around the Pole
8.3.5 Wrap 4 No’s Guy rope at the top of Rail Pole.
8.3.6 Deploy 04 persons for holding the guy rope.
8.3.7 Fix the Tirfor
8.3.8 Check the firmness of anchorage point.
8.3.9 Start pulling the Pole by Tirfor.
8.3.10 Don’t allow any jerk load.
8.3.11 Don’t use any pipe for extending the lever of Tirfor.
8.3.12 Check the alignment by plumb bob after erecting the pole.
8.3.13 Wrap the guy rope around the guy pin, after Pole reaches to its desired
position.
8.3.14 Place the shuttering board for concreting of Rail Pole as per specification
8.3.15 Place support of shuttering board to restrict the displacement of the same.
8.3.16 Pour the concrete.
8.3.17 Remove the shuttering board after setting of concrete.
8.4 For installation of Pole by using Pick and Carry type Crane.
8.4.1 Select Crane of adequate capacity to erect rail pole
8.4.2 Check the Load Test certificate of Crane.
8.4.3 Check the validity of license of Crane Operator.
8.4.4 Check the physical condition of crane by using Crane Inspection
Checklist ( IM 09- A 07)
8.4.5 Check the lifting tools and tackles i.e. – Sling, D – Shackle etc. for the
suitability of the activity.
8.4.6 Check the load test certificate of lifting tools and tackles.
8.4.7 Deploy experienced rigger and signalman.
8.4.8 Make slinging arrangement of pole.
8.4.9 Fix the sling in the hook of the crane.
8.4.10 Wrap a Guy rope at the top of Rail Pole. Also wrap one more guy rope
at the 2-3 M level from the bottom of the pole.
8.4.11 Deploy 02 persons for holding the guy rope to control the abrupt swing
during lifting by crane.
8.4.12 Lift the Pole by Crane.
8.4.13 Check the alignment by plumb bob after erecting the pole.
8.4.14 Drive guy pin at 04 sides of the crane.
8.4.15 Wrap the guy rope around the guy pin.
56
8.4.16 Place the shuttering board for concreting of Rail Pole as per specification
8.4.17 Place support of shuttering board to restrict the
displacement of the same.
8.4.18 Pour the concrete.
8.4.19 Remove the shuttering board after setting of concrete.
8.4.20 Place the ladder
8.4.21 One person should hold the ladder
8.4.22 Climb through the ladder
8.4.23 Anchor the safety harness
8.4.24 Remove the guy rope from pole
8.4.25 Climb down from ladder.

9.1 Electrical Clearance from existing line from our newly erected pole or insulator
fixed to prevent accidental contact with metallic part.
9.2 Compaction and verticality of the pole.
9.3 Post shutdown formalities fulfilled in case of shutdown related activity.
10. RECORD
10.1 Pre Task Plan
10.2 PEP talk
10.4 Shutdown checklist cum LC permits
11. DISTRIBUITION
BEL-PT&D: Project Manager (PT&D), Section-In-Charge / Site Engineer/Site Supervisors
57
f

Safe Operating Procedure: Structural
Material Fitting
1. PURPOSE:
This is to provide documented operating procedure for executing the fixing of structural
materials on Pole activity in a safe manner.
2. SCOPE:
It covers the safe operating procedure for Structural Erection activity and related sub
activities as mentioned ow, to be followed by BEL Employees, Subcontractors,
Supervisors and Workmen working at PT&D Sites:
Sub Activity Geographical Customer

Varieties Needs
Handling and loading of material at store Plain land MS (Mild Steel)
Structure
Shifting of material by vehicle on road Hilly area GI (Galvanizing
Iron) Structure
Manual erection of structural steel i.e. cross arms, Top Forest area
supports, etc. on single pole.
Manual erection of structural steel and accessories for Riverine Area
Equipment (like 10KVA/ 16KVA/ 25KVA transformer on
single pole and equipment such as LA, DO fuse/HG
Fuse, AB switch/GOS, Distribution box, Meter box etc.).
Manual erection of structural steel material on double Desert area
pole like DP structure, cross bracing, support for AB
switch, DO fuse, LA, Distribution box and Meter box and
all necessary equipment such as DO/DOLO/HG Fuse,
AB Switch/GOS, LA, Meter box
3.4 Approved Pre Shutdown Survey
3.6 Approved procedure for execution of shut down work
3.7 Applicable CODES as per contract
3.8 Approved project EHS plan
3.10 Field Quality Assurance Plan (FQAP)
58
4. RESPONSIBILITY:
Section In Charge, Site engineer, Site qualified field supervisor and sub-contractor
of PT&D IC.

5.1 Calibrated measuring instruments
5.2 Rope Pulley
5.3 PP rope
5.4 Tools bag
5.5 Aligning Pointed Crow Bar
5.6 2lb Hammer
5.7 Spanner Set
5.8 Screw Driver
5.9 Cutting Plier
5.10 FRP Ladder
5.11 Electrician tools
5.12 Temporary earthing system – safety grounding jumpers
5.13 LOTO system.
6. Personal Protective Equipment AND Safety Gadgets:

7.1 Approved Pre Shutdown Survey shall be available at location if required
7.2 Approved Pre Task plan shall be available at location if required.
7.3 Approved Survey Drawing shall be available at the location
7.4 Inspected Pole and accessories in good condition shall be available at the location
7.5 All work permits shall be obtained before stating of work.
59
7.6 Pep talk on the activity shall be given to the working crew
7.7 Location specific emergency plan shall be made available to the crew leader,
7.8 Approved Field Quality Assurance Plan (FQAP) and Checklist for the procedure
shall be available at the location with crew leader, frontline supervisor and the
engineer in charge.
7.9 Accepted installation checklist of Structure.
7.10 First Aid Kit
7.11 PPE and other safety gadget required: Safety helmet, Safety Shoes, Hand
Gloves, Reflective jacket, full body harness, Helmet mounted induction tester,
Multi tester, Discharge rod and earth spike.
7.12 Screened and trained supervisor and screened qualified Workmen
7.13 Health check-up and Height pass for workmen to work at height
8.1 Handling and loading of material at store:
8.1.1 Wear required PPEs like safety helmet, safety shoes and thermo-latex
hand gloves.
8.1.2 Check the availability of all required materials at store.
8.1.3 Inspect the stacking area to ensure there is no insect and snake.
8.1.4 Place the vehicle nearest to the stacking location by help of signal man
and while reversing use reverse horn and light.
8.1.5 Do not allow any worker to stand in between vehicle and material.
8.1.6 During lifting and handling material follow the ow mentioned steps.
9.1.6.a Keep the back straight.
9.1.6.b Grip the material tightly.
9.1.6.c Hold the material close to the body.
9.1.6.d Use body weight while lifting material.
9.1.6.e Keep chin up right.
8.1.7 Do not lift more than 30 Kg weight per person at a time.
8.1.8 Tie or secure the material at vehicle to prevent accidental fall of material
from vehicle.
8.2 Shifting of material on road:

8.2.1 Do not allow any worker to travel along with material on the same vehicle.
8.2.2 Do not drink and drive.
8.2.3 Follow the road traffic rules (Speed limit etc.) while drive.
8.2.4 While reversing vehicles use reverse horn, reverse light and signal man.
8.2.5 If required, stop the vehicle besides the road at the time of adverse
weather condition like heavy rain, thunderstorm etc.
60
8.2.6 Avoid over projection of material beyond the body of the vehicle.
8.2.7 Tie Red flag in case of material projection from the vehicle.
8.2.8 Ensure that the projection of the material should not exceed one third of
the length.
8.2.9 Put wheel stopper while the vehicle is in rest.
8.3 Manual erection of structural steel like V-cross arm, Top support, and
single pole cut point etc. for HT and LT bracket and insulator etc.
8.3.1 Barricade the working area by warning tape and safety cone.
8.3.2 Use tools bag for carrying all tools and tackles like wrench, spanner etc.
8.3.3 Wear required PPEs like safety helmet, safety shoes, thermo-latex hand
gloves etc. while handling material.
8.3.4 Fix FRP ladder on the pole
8.3.5 Wear full body harness to climb on the ladder and tie the ladder top to
pole with rope to secure.
8.3.6 After reaching on the pole height, anchor the waist t of full body harness
around the pole.
8.3.7 Lift any material at height by means of 20mm PP rope only.
8.3.8 Check all ropes and pulley to ensure the tools and tackles are safe for
use.
8.3.9 Lift clamp for anchoring rope pulley and fix the clamp on the pole.
8.3.10 Do not allow anyone to stand ow the height-work area.
8.3.11 Lift the rope pulley and fix on the erected clamp.
8.3.12 Lift the structural material like V-cross/ top bracket etc. and erect the
material on the pole one by one.
8.3.13 Check the alignment by sprit level and tight nuts and bolts properly.
8.3.14 Remove all the loose material from height.
8.4 Manual erection for DTR (Distribution Transformer) structure and

accessories
8.4.1 Check all structure physically for lifting points
8.4.2 Use lifting arrangements
8.4.3 Secure and balance the structural member with lifting sling
8.4.4 Ensure that all sharp edges on structural steel support are removed
8.4.7 Fix FRP ladder on the pole.
around the pole.
8.4.10 Lift clamp for anchoring rope pulley and fix the clamp on the pole.
8.4.11 Do not allow anyone to stand ow the height work area.
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8.4.12 Lift the rope pulley and fix on the erected clamp.
8.4.13 Lift the support of every equipment first and fix on the pole.
8.4.14 Lift the equipment (LA, AB Switch, DO Fuse and DB) and fix on the
erected support.
8.4.16 Remove all the loose material from height.
8.5 Manual erection of structural steel material on double pole like Double
Pole (DP) structure, cross bracing:
8.5.1 Ensure that all sharp edges on structural steel support are removed
before erection.
8.5.2 Check all equipment physically to ensure the equipment is free from any
defect and conduct test if required before erection.
8.5.5 Fix FRP ladder on both the poles and wearing full body harness, two
workers having valid height pass climb on the poles.
around the pole and hook the t.
8.5.8 Lift clamp for anchoring rope pulley and fix the clamp on both the poles.
8.5.9 Do not allow to stand ow the height work area when material is being
lifted and erected.
8.5.10 Lift two rope pulleys for both the poles and fix on the erected clamp.
8.5.11 Tie PP rope of the both pulleys at the both end of the structure steel.
8.5.12 Lift the material by help of both pulleys simultaneously.
8.5.13 Anchor the both end of the structure with clamp and nuts and bolts on
the poles.
8.5.15 Follow the same procedure to erect all the structures at different
elevations on double pole as per approved drawing.
8.5.16 Lift all equipment one by one and fix on the erected support structure.
8.5.17 Remove all loose material from height.
8.6 AB Switch:
8.6.1 Provide jumpers from HT new line to AB switch; drop out fuse and to DTR
bushing.
8.6.2 AB switch clearance from phase to phase must be 760 mm and from
phase to ground clearance must be 460 mm maintained.
8.6.3 Provide AB switch handle at a height of 1 to 1.2 m from the ground level.
8.6.4 Provide earthing of Handle of the AB switch using flexible braided copper
wire as per specification.
8.6.5 Check the alignment and operation of the AB switch.
8.6.6 The connecting pipe of the AB switch is to be laid through proper guide.
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8.6.7 Mark the feeder details near the handle.
8.6.8 Check the rigidness and tightness of the terminal connection at ends.
8.7 Lightning Arrestor:

8.7.1 Distribution transformer shall be fitted with LA’s to protect transformer
from any electrical surge.
8.7.2 Provide jumpers from HT new line to LA using wedge connector/PG

Clamp and shall be erected as per approved drawings.
8.7.3 Provide earthing of LA using separate earth conductor and earth pit.
8.7.4 Check the rigidness and tightness of the terminal connection at ends.
8.8 Drop Out Fuse:

8.8.1 DO fuse shall be used to protect and isolate transformer on HT side in
case of over current and earth faults.
8.8.2 Provide earthing for all non-current carrying metal parts.
8.9 DTR Meter:

8.9.1 DTR meter shall be provided on the LT side for energy audit purpose.
8.9.2 As per drawing meter shall be installed
8.9.3 Meter box shall be supported properly.
8.9.4 The control cable should be properly supported and protected against
external damages.
9. POST OPERATIONAL CHECK:

9.1 Each commissioned meter should record correctly as per client requirements.
9.2 Alignment and tightness of Connection – there should not be any sparking.
9.3 Acceptance values for IR shall be as per ow table :
Voltage of the Winding Minimum Safe IR in mΩ
11kV 200
LT 100
9.4 Remove all tools and tackles from height and bring back to site store.

10.1 Filled check list for structural steel and equipment Erection.
10.2 Pre task Plan
10.3 PEP talk
63
11. DISTRIBUITION
BEL-PT&D -> Project Manager (PT&D), Section-In-Charge / Site Engineer/Site
Supervisors
64
f

Pole (Stay & Earthing)
1. PURPOSE:
To provide documented operating procedure for Installation of pole (Stay and Earthing)
activities to be executed in a safe manner.
2. SCOPE:
The scope is to cover safe operating procedure for installation of pole (Stay & Earthing)
in the following variables.
Sub Activity Geographical Variety Customer Needs
Handling of material Plain land Concrete slab, Stone
Shifting of material Hilly area Pad, Stay grouting and
Excavation for stay pit and earth pit Forest area 6/8/10 SWG GI wire
Grouting and backfilling for stay set Riverine Area

Desert area
Backfilling for earth pit

Binding and fixing of stay wire and earth lead
3.1 Contract technical specifications
3.2 Client approved drawing for Stay and Earthing
3.3 Initial detailed Survey drawings prepared for Bill of Quantity (BOQ) 3.4
BEL EHS Manual
4. RESPONSIBILITY:
Section in Charge, Site engineer, Site supervisor and sub-contractor of PT&D
IC.

5.1 Crow bar
5.2 Spade with wooden handle
5.3 12mm PP rope
5.4 2lb Hammer
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5.5 Spanner Set
5.6 Screw Driver
5.7 Cutting Plier
5.8 Ladder
5.10 Road safety gadgets (Road safety cone, barricading tape, red and green flag
and whistle).
5.11 Measuring tape
6. PERSONAL PROTECTIVE EQU IPMENT & SAFETY GADGETS:
Helmet with
Induction
Sensor
Fall
arrester
with Life Induction
line tester

7.1 Screened and trained supervisor and workmen shall be available for
execution of work.
7.2 Approved Pre task plan shall be available at location.
7.3 Approved Pre Shutdown Survey shall be available at location.
7.4 Approved drawing shall be available at the location.
7.5 Checked and ensured that there is no underground utility.
7.6 All work permits shall be obtained before starting of work.
7.7 Pep talk on the activity shall be given to the workforce.
7.8 Location specific emergency plan shall be made available to the gang leader,
7.9 Approved Field Quality Approved Plan (FQAP) and Checklist for the
procedure shall be available at the location with crew leader, frontline
supervisor and the engineer in charge.
7.10 7.10 Required tools and tackles
7.11 PPEs and First Aid Kit.
66
8.1 Excavation for stay pit and earth pit:
8.1.1 Check the type of soil and ground water level.
8.1.2 Collect information about underground utilities from appropriate authority or
use cable/ metal detector.
8.1.3 In case of existence of underground utilities, get required clearance permit
from the appropriate authorities and ensure isolation of the utility before start
of activity.
8.1.4 Use crow bar and spade having wooden handle for manual excavation.
8.1.5 Do Step cutting to minimize the possibilities of collapse.

8.1.6 Stack the excavated soil at least 1.5 meters away from edge of excavated pit
or half of the depth of the pit whichever is more.
8.1.7 Provide barricade around the excavated area by warning tape and safety
cone if the work not completed at a time.
67
8.1.8 Use bucket for dewatering from pit.
8.1.9 Do not carry any vertical cut to avoid soil collapse.
8.1.10 Do not carry any undercut also to avoid collapse of soil.
8.1.11 Do not wear any loose clothing and metal ring.

8.1.12 Do not work alone.
68
8.1.13 Wear Safety helmet, safety shoes/ gum boot, reflective jacket and hand
gloves.
8.1.14 Never leave any excavated pit without barricade.
8.2 Grouting and backfilling for stay set:

8.2.1 Place the stay rod at an angle along with concrete slab/ stone pad as per the
approved drawing.
8.2.2 Fill the excavated pit with soil and brick bats and compact properly.
8.2.3 For grouting of stay set, prepare the concrete mixer by wearing PVC hand
gloves along with basic PPEs.
8.2.4 Pour the concrete mixer into the pit up to the required level as per
specification.
8.2.5 Keep minimum distance from edge of excavation while pouring.
8.2.6 Backfill with soil for the remaining part of the pit and do compaction.
8.3 Backfilling for earth pit:
8.3.1 Wear thermos-latex hand gloves along with basic PPEs.
8.3.2 Place the earth spike in vertical position.
8.3.3 Pour the soil, charcoal and salt layer by layer as per specification.
8.4 Binding and fixing of stay wire & earth lead:
8.4.1 Use ladder for fixing and binding stay wire
8.4.2 Wearing full body harness climb on the pole and fix and bind stay wire with
stay clamp.
8.4.3 Carry out binding works with guy insulator on ground level.
8.4.4 Fix the earth lead wire in between pole bracket and earth electrode.
8.4.5 Do not allow throwing of material from height as well as from ground.
9. POST OPERATIONAL CHECK:

9.1 Check tightness of binding.
9.2 Check the lead joint of earth electrode as per approved drawing
9.3 Tightness of nuts and bolts.
9.4 Removal of all loose materials from height.
69
10. RECORD
10.1 Pre task Plan
10.2 PEP talk
11. DISTRIBUITION
supervisors
70
f

Safe Operating Procedure: Stringing of
Conductor upto 33 kV
1. PURPOSE:
To provide documented operating procedure for stringing activity to be executed in a safe
manner.
2. SCOPE:
It covers the safe operating procedure for stringing activity to be executed in Utility Power
Distribution (UPD) projects, to be followed by BEL Employees, Subcontractors,
Supervisors and Workmen working at PT&D Site.
2.1 Stringing near existing line.
2.2 Stringing of new line which crosses/near the line.
2.3 Re-stringing of existing conductor.
2.4 Dismantling of existing HT/LT line. 2.5 Re-conductoring of existing line
2.6 Phase Conversion of LT lines.
3.1 Contract Technical Specifications.
3.2 Approved Pre Task Plan.
3.3 Approved Survey Drawings or Initial Detailed Survey drawings.
3.4 Client approved structural drawings
3.5 Indian Electricity Rule 1956
3.6 BEL EHS Manual
3.7 Project Quality Plan
4. RESPONSIBILITY:
Section In Charge, Site engineer, Site supervisor of PT&D IC.
4.2 Responsibility of checking of implementation of this procedure lies on site EHSO.
5.1 FRP Ladder

5.2 20mm and 12mm PP rope
5.3 Come along Clamp
5.4 Pulley
5.5 Tirfor
5.6 Insulated Crowbar
5.7 Spanner set and Screw driver set
71
5.8 Discharge Rod with spike
5.9 HV Tester
5.10 Multi tester (Pen Type)
6. PERSONAL PROTECTIVE EQUIPMENTS A ND SAFETY GADGETS
Helmet With
Induction
Sensor Induction Tester
7. PRE-REQUISITE / PRE OPERATIONAL CHECK:

7.1 Inspect physical site location to identify power sources in the closed vicinity
of working area.
7.2 Qualified, Trained supervisor
7.3 Approved Pre Task Plan 7.4 Trained and skilled workmen.
7.5 Shut Down Clearance (HT / LT) cum Work Permit for Transmission Line, APDRP
/ Rural Electrification and other Works
8.1 BEFORE START OF STRINGING ACTIVITY:
8.1.1 Supervisor and sub-contractor supervisor/Gang leader should do the walk
over survey with approved PTP
8.1.2 Line verification should be done in person to prevent induction / back feeding
from other sources and understand the hazards noticed in the PTP/involved
other than that (in case of shut down jobs).
8.1.3 Supervisor has to ensure the availability of sufficient workmen of required
category for the activity.
8.1.4 Check and Ensure the existing pole condition by visual check
72
8.1.5 Check particularly at the bottom for any cracks in case of PCC and PSCC
poles, if any cracks/damage found then ensure additional/temporary guy/stay
arrangement being provided.
8.1.6 Check for Damage / Detoriation, Rebar exposure in case of RCC Pole,
provide additional guy arrangement on observing damages.
8.1.7 For Steel Pole, Check for rust at the bottom by excavating upto 6 inches, if
excessive rusting is found, additional guy arrangement to be provided.
8.1.8 Check and Ensure the building clearance, if sufficient clearance not available,
ensure it by providing side extended cross arm.
8.1.9 Check and Ensure the new pole mounting/backfilling, soil compaction and its
verticality
8.1.10 Check and Ensure the good condition of Dead end poles. Check and Ensure
the guy support / stays thoroughly on both ends of the stringing, ensure it in
good condition and packing. Ensure appropriate strain insulator should be
used for the type of line
8.1.11 Check and Ensure the Stud pole at turning/angle deviation/skew points and
its position in absence of stay set.
8.1.12 Ensure the position of stay sets is against the tension (Position of Guy/Stay
as HT/LT).
8.1.13 If the guy wire is passing through the another circuit of HT/LT, ensure double
break/strain insulator shall be used of appropriate grade (15 KN for 11kV and
8 KN for LT)
8.1.14 Provide all necessary PPE-Personal Protective Equipment like Induction
tester (Helmet mounted), Safety t and Safety shoes to all workmen.
8.1.15 If Line Crossing occurs in the work area limit take Line shut down and work
permit from the State Electricity Board before starting of the work shall be
taken and also fill LC work permit
73
8.1.16 Provide Red flags and caution (Danger) boards at all the switching points,
which can be inlet points for switching on electricity to the Existing Line near
work area limit.
8.1.17 Supervisor shall authorize the gang leader to start the work and indicate to
him the boundary limits within which the gang leader should work.
8.1.18 Further the supervisor shall earth both the ends using discharge rods and all
the ends of line leading to the working area and keep them continuously
earthed before handing over the work permit. Spike rod shall be inserted first
to ground then discharge rod shall be connected to the conductor and during
removal, discharge rod shall be removed first then spike rod.
8.1.19 Pour water/salt water around the area of spike rod to keep the resistance
lower.
74
8.1.20 Provide Ladder for Climbing on the pole, tools and tackles for tying the
conductors with the insulators, Rope and pulley for stringing the conductor.
8.2 Installation of Guy Set/Stay set/Stud Pole:-

8.2.1 Mark the Guy pit / Stay pit location as per the availability of space and ensure
the distance from the pole should be 30 Degree to 45 degree as per
specification.
8.2.2 If sufficient space not available, decide the type of
Guy/Stay as 8.2.2.a Bow Stay Overhead Guy / Stay by
extending the stay to one span.
8.2.2.b Type of back support by providing stud pole.
8.2.3 Excavate the Guy Pit / Stay pit upto the specified depth. Excavation should
be perpendicular to the line direction.
8.2.4 Install the Guy Rod /Stay Rod and anchor the same with proper packing of stone
pad or concreting (as per specification)
8.2.5 Fix the Guy clamp at appropriate location of load point.
75
8.2.6 If it is multi circuit pole Guy/Stay has to be provided for deviation /tapping circuit.
8.2.7 Use appropriate strain insulator depends on the voltage grade of line.
8.2.8 Use two strain insulator at different location i.e. 1.5 M apart in case the guy wire
passes through another circuit.
8.2.9 Ensure the position of strain insulator from the ground should be minimum of
3000 mm from ground level.
8.2.10 Select the stud pole, should be less than the height of line pole.
8.2.11 Mark the stud pole planting location. Should be 20-30 degree from the line pole
8.2.12 Excavate for the erection of stud pole with angle upto the depth as per
specification or 1000 mm.
8.2.13 Erect the stud pole, place it at the loading point, fix it with the line pole with stud
pole clamp.
8.2.14 Back fill the pit with proper compaction.
8.3 DURING STRINGING ACTIVITY:-
8.3.1 Shift the conductor drum/ required conductor ring to the location.
8.3.2 Check Ladder, Tools and Tackles, Rope, Pulley, Come along clamp, tirfor etc.
for its rigidity before starting the work.
8.3.3 Fix the ladder properly and one person should hold the ladder at the time of
climbing. Anchor the harness after reaching the required height, anchor the
waist t with pole after that.
76
8.3.4 Make a bamboo scaffold in case of road crossing for passing the conductor
overhead without creating any obstacle to traffic
8.3.5 Deploy one person with red flag to control the traffic.
8.3.6 Remove the existing conductor in such a fashion that at least one phase shall
remain in the pole until the new line is strung. (Priority first middle conductor,
then one side conductor, then other side conductor, so as to balance load
applied).
8.3.7 Tension the conductor using “Come along clamp/Tirfor/ Rope Pulley
8.3.8 Ensure the proper tension load / sag-visually.
8.3.9 Once the required tension and ground clearance is achieved transfer the load
from come along clamp to the string.
8.3.10 After checking for the acceptance level remove the Pull lift/pulley, come along
clamps, rope etc.
8.3.11 Ensure that the pave out of second conductor should be done only after the
stringing and pin binding of first conductor.
8.3.12 All the joints or splices shall be made at least 30 M away from the pole. No
joints or splices shall be made in spans crossing over main roads, railway line
and Small River spans. Not more than one joint per conductor per span shall
be allowed.
8.4 AFTER STRINGING ACTIVITY:-
8.4.1 All men and materials shall be removed from the workplace.
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8.4.2 The gang leader shall discharge the work permit and return the same to safety
steward

Reinstate all the utilities.
10. RECORDS
10.1 PEP talk
10.2 Permit to work between supervisor, gang
leader and worker.
10.3 PTP (EHS/UPD/SWP/CL/2A).
10.4 Shutdown clearance (HT/LT) cum work permit for transmission line, APDRP/ Rural
Electrification and other works
10.5 Checklist for shutdown activity
11. DISTRIBUTION
BEL PT&D -> Project Manager (PT&D), Section-In-Charge / Site Engineer/Site
Supervisors.
78
f

AB cable
1. PURPOSE:
To provide documented operating procedure for laying of Aerial Bunched Cable in a safe
manner.
2. SCOPE:
The scope is to cover safe work procedure of AB Cable (HT/ LT) laying in the following
variables.
Loading of cable drum and accessories Plain land HT AB Cable / LT Ab Cable
Shifting of cable drum and accessories Hilly area
Unloading of cable drum and accessories Forest area
Installation of fittings and accessories Riverine Area
Installation of AB cable Desert area
3.5 Approved Safety Shutdown Procedure if required
3.7 Daily work permit
3.8 PEP talk report
4. RESPONSIBILITY:
Section In Charge, Site engineer, Site qualified field supervisor and sub-
contractor of PT&D IC.

5.1 Insulation tester
5.2 Torque wrench
5.3 Wire rope sling
5.4 D-shackle
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5.5 Spanner Set of D-E, Ring type
5.6 Cable Jack and Shaft/ turn table
5.7 Pulley
5.8 FRP Ladder
5.10 Telescopic Discharge Rods with spike and HV tester
5.11 Induction Tester(Non-Contact Voltage Tester, helmet mounted)
5.12 Clamp meter for earth resistance measurement
5.13 Multi tester

5.14 Temporary earthing system – safety grounding jumpers
5.15 LOTO and token system
6. Personal Protective Equipment:
Helmet With Induction

Induction tester
Sensor

7.3 Approved SOP for Shutdown shall be available at location if required.
7.4 Approved Survey Drawing shall be available at the location.
7.5 Inspected and tested cable and accessories in good condition shall be available
at the location.
7.6 Inspected cable jack and shaft/ turn table in good condition shall be available.
80
7.10 Approved Field Quality Approved Plan and Checklist for the procedure shall be
available at the location with crew leader, frontline supervisor and the engineer
in charge.
7.11 Required tools and tackles
7.12 PPEs and First Aid Kit
7.13 Screened and trained supervisor and screened and qualified Workmen(
minimum 8)
8.1 Loading and unloading of cable drum and accessories:
8.1.1 Loading by Derrick Pole:
8.1.1.a Check the physical condition of derrick pole to ensure that the derrick
pole is safe for use.
8.1.1.b Ensure availability of signal man along with the vehicle and reverse
horn and light of the vehicle.
8.1.1.c Do not allow any person to stand in between the vehicle and material.
8.1.1.d Select the wire rope sling and shaft according to the weight of the cable
drum.
8.1.1.e Check the physical fitness of shaft and wire rope sling.
8.1.1.f Fix the shaft on the cable drum and fix the wire rope sling to lift the
drum.
8.1.1.g Lift the cable drum by means of chain pulley block.
8.1.1.h Do not allow any person to stand ow the lifted cable drum.
8.1.1.i Place the vehicle ow the cable drum with help of signal man.
8.1.1.j Lower the cable drum to place on the vehicle and tie the drum with the
vehicle with ratchet t
81
8.1.1.k Place additional stopper at both sides of the drum to prevent accidental
roll over, shift and fall from vehicle.
8.1.2 Loading by new generation hydra crane/ truck mounted crane:

8.1.2.a Check the crane physically to ensure the crane is safe for use.
8.1.2.b Place the crane or out rigs of Truck Mounted Crane (TMC) on firm
ground.
8.1.2.c Select the wire rope sling and shaft according to the weight of the cable
drum.
8.1.2.d Check the physical fitness of shaft and wire rope sling.
8.1.2.e Fix the shaft on the cable drum and fix the wire rope sling to lift the drum
and tie the tag line with the drum.
8.1.2.f Barricade the swing area of crane.
8.1.2.g Lift the cable drum by means of crane and place on vehicle.
8.1.2.h Tie the cable drum with vehicle and place additional stopper at both
ends of the drum to prevent accidental fall from vehicle.
8.1.2.i Keep the wire rope sling and shaft along with the drum on the vehicle
for further use during unloading.
8.1.3 Loading and Unloading of accessories on vehicle:

8.1.3.a Wear hand gloves along with basic PPEs.
8.1.3.b Follow kinetic method of lifting and shifting of material.
1 3
82
8.1.3.c Do not lift or carry excessive weight (not more than 30 Kg) during
handling.
8.1.3.d Ensure that sharp edges are removed before start of handling.
8.1.4 Shifting of cable drum by vehicle:

8.1.4.a Do not allow any worker to travel along with transformer on the same
vehicle.
8.1.4.b Do not drink and drive.

8.1.4.c Follow the road traffic rules (Speed limit) while drive.
8.1.4.d While reversing use reverse horn, reverse light and signal man.
8.1.4.e If required, stop the vehicle besides the road at the time of adverse
8.1.4.f Put wheel stopper while the vehicle is in rest.
8.1.5 Unloading of cable drum by Truck mounted crane/ new generation hydra
crane:
8.1.5.a Inspect the crane physical to ensure fitness of the crane.
8.1.5.b Place the crane or out rigs on the firm ground.
8.1.5.c Barricade the working area and do not allow any worker with in the
swinging area of the crane by warning tape and safety cone.
8.1.5.d Ensure wearing of hand gloves during handling of drum.
8.1.5.e Fix the wire rope sling and shaft for unloading the drum from the vehicle.
8.1.5.f Signal man must be available to give signal to the crane operator.
8.1.5.g Unload the drum and provide stopper on both sides of drum to prevent
accidental run and hit.
83
8.1.5.h Remove the truck mounted crane or vehicle and crane from the
location.
8.1.5.i Erect the drum on the turn table or on jack to uncoil the drum.
8.1.6 Installation of Fittings and Accessories:

8.1.6.a The following hardware fittings and accessories are used to install,
erect and join the aerial bunched cable.
8.1.6.b Fix the FRP ladder on the pole and wearing full body harness along
with basic PPEs the person having valid height pass climb on the pole.
8.1.6.c After reaching at height, fix the waist t of full body harness and hook the
lanyard.
8.1.6.d Use 20mm PP rope for lifting of material from ground and tool bag for
carrying and holding tools and Tackles at height.
8.1.6.e Do not allow any worker to throw any material from ground as well as
from height.
8.1.6.f Do not allow any worker to stand ow the height work area.
8.1.6.g For terminal end pole lift pole clamp, eye hook, dead end clamp and fix
on the pole. ( see figure – 1)
Figure – 1
84
8.1.6.h For suspension poles, lift the pole clamp, eye hook and suspension
clamp and fix on the pole. (See figure – 2).
Figure – 2
8.1.6.i Use Nylon Tie – These ties are used for tying the conductors with the
messenger wire to prevent the phase conductors from damaging by
making contact with suspension clamp. The nylon tie is made of
weather resistant black nylon.
8.1.6.j Spilt Plastic Tube (see figure 3) – These tubes are used to prevent the
suspension clamp to chaff against the cable. The cable is made of black
weather resistant material.
8.1.6.k Torque wrench is to be used for fixing various line materials and
components such as suspension clamp for conductor, whenever
recommended by the manufacturer of the same.
85
Figure – 3
8.1.7 Installation of AB Cable (HT/ LT):
8.1.7.1 The average span proposed for AB cable installation is approximately

40 M as per specifications.
8.1.7.2 AB cable drum shall be shifted to the spot and to be uncoiled from the
drum by using jack and shaft as per requirement.
8.1.7.3 Ensure that the drum is placed perfect horizontal position to avoid
uneven load on jack.
8.1.7.4 Ensure that the insulation of the conductor does not get damaged
during installation.
8.1.7.5 Do not allow Dragging of AB cable on the ground.
8.1.7.6 Barricade the working area by warning tape and safety cone.
8.1.7.7 Pave the AB cable along the route

8.1.7.8 Provide the temporary guys at both the ends.
8.1.7.9 Check the condition and strength of the terminal before applying
tension.
8.1.7.10 Make up the AB Cable messenger wire at one End (see figure 1)
8.1.7.11 Tension the AB Cable messenger wire using “Pulley” at the another
end.
8.1.7.12 Once the required tension and ground clearance is achieved transfer
the load from pulley to the string.
86
8.1.7.13 After checking for the acceptance level remove the pulleys, PP rope
etc.
8.1.7.14 The messenger wire of bunched cable resting on a pulley is separated

from the cable by separating wedges and inserted in the conductor
groove of the suspension clamp using the Spilt Plastic Tube (see figure
-3,4).
Figure – 4
8.1.7.15 The bolt is tightened to a torque of 20 KN after which the pulley and
wedges are to be
removed.
8.1.7.16 The cable is tied to the messenger wire with nylon tie on both sides of
clamps.
8.1.7.17 Check the connection, guy sets and earthing of the complete line and
Insulation
Resistance (IR) test to be done before charging.
8.1.7.18 It has to be ensured that normal services are not interrupted and any
property is not damaged during stringing operations.
8.1.7.19 Terminal pole condition and strength of the temporary guy to be
checked before applying tension.
8.1.7.20 Cable roller should be used on all pole
87
8.1.7.21 Tension the AB Cable messenger wire using “Come along clamp &
“with pull lift” at the END B.
8.1.7.22 Once the required tension and ground clearance is achieved transfer
the load from come along clamp to the string.
8.1.7.23 After checking for the acceptance level remove the pulleys, come along
clamps, rope etc.
8.1.7.24 Never tying the roller in the clamp directly.
8.1.7.25 Place the FRP ladder opposite side of cable
88
8.1.7.26 Suitable arrangement of scaffold type shall be made for crossing of
road
8.1.7.27 Never lift the Cable by tying with safety t during climbing on
the pole.
8.1.7.28 Tractor shall not be used for Stringing work
89
8.1.7.29 Shut-down shall be obtained wherever required.
8.1.7.30 Check IR values- phase to phase and phase to earth with Insulator
tester – Phase to Phase and Phase to earth values should be Infinite
90° Pole Location
Figure-5
90
Figure 6
Figure 7
91
Figure 8
Figure 9
92
Figure 10
8.1.8 Special precautions:

8.1.8.a Working at hilly area:
8.1.8.a.1 Do not allow any worker to stand or work at the edge of steep slope
or land.
8.1.8.a.2 Get information regarding land sliding from authorized center and
do not allow any worker to go the work area if land sliding is there.
8.1.8.a.3 Use life line and fall arrestor if required.
8.1.8.a.4 Do not allow to use tree as a support.
8.1.8.a.5 Carry carbolic acid and bleaching power to prevent from insect and
snake hazard.
8.1.8.b Working at forest:
8.1.8.b.1 Do not enter into the forest area without permission from concerned
authority.
8.1.8.b.2 Use and arrange forest guide while entering and working inside a
forest.
8.1.8.b.3 Do not allow to smoke inside forest to prevent fire hazard.
8.1.8.b.4 Travel on by closed vehicle.
93
8.1.8.b.5 Keep carbolic acid and bleaching power for snake and insect.
8.1.8.b.6 Use binocular to identify wild animal from far away.
8.1.8.c Working at Riverine area:
8.1.8.c.1 Check the water flow speed of the riverine area and do not allow any
worker to enter the riverine area if the flow speed is very high.
8.1.8.c.2 Ensure availability of trained swimmer along with the worker crew.
8.1.8.c.3 Use boat and life jacket while work.
8.1.8.c.4 Use stick to check the level of water at that area.
8.1.8.d Working at Desert area:
8.1.8.d.1 Wear full body cover/ apron
8.1.8.d.2 Ensure the availability of sufficient drinking water.
9. Post Operational Check:

9.1 Ground clearance
9.3 Removal of all loose materials from height.
10. RECORD
10.1 Checklist for installation of AB cable
10.2 Pre task Plan
10.3 PEP talk
11. DISTRIBUITION
BEL PT&D -> Project Manager (PT&D), Section-In-Charge / Site Engineer/Site Supervisors
94
f

Safe Operating Procedure: Under Ground
Cabling
1. PURPOSE:
To provide Operating Procedure for Under Ground Cable laying activity to be executed
in a safe manner.
2. SCOPE:
It covers the safe operating procedure for trenching, laying of underground cables, testing
and back filling of all types of cables at the project.
3.3 Approved shutdown procedure
3.4 Technical Specifications
3.5 Approved survey report and drawing
3.6 Route clearance copy from concerned authority (Municipality, Electricity board,
Telephone agency, gas transmission authority, Water distribution authority etc.)
3.7 IS -1255 code of practice for installation and maintenance of power cables up to
and including 33 kV rating
3.8 Approved Guaranteed Technical Particulars (GTP) of U/G cables
3.9 Manufacturer test certificate/operating procedure for Cable Jack , Shaft and
Winch Machine (WM)
3.10 Calibration certificate for IR tester and HV (High Voltage) test kit.
4. RESPONSIBILITY:
Section In Charge, Site engineer, Site qualified field supervisor of PT&D IC.

5.1 Spade
5.2 Shovel
5.3 Insulated Crow bar
5.4 Road meter
5.5 Insulation tester
5.6 Continuity Tester,
5.7 Pulling Rope Meter or Dynamometer
5.8 Motor driven roller –(If required at Site)
5.9 Warning Tapes
95
5.10 Plastic cap or heat shrinkable cap
5.11 Winch ( If required as per field conditions)
5.12 Cable drum jack,
5.13 Cable identification tags
5.14 Clamps for fixing / dressing of cables. Cable rollers.

5.16 Barricading tape/net
5.17 Hard barricade with retro reflective sticker
5.18 LED light (chain light)
5.19 DG operated light mast
5.20 Warning board/diversion board
5.21 Safety Cone
5.22 Pump for dewatering
5.23 Shoring /shuttering if required
5.24 Excavator
5.25 New generation F-15 crane
5.26 Trailer/truck
5.27 Red Flag/Blinking light
5.28 Blow lamp
5.29 Electrician tool kit for jointing
5.30 Underground utility detector
5.31 Fire extinguisher
5.32 PP Rope
Fall arrester
with Life line
Helmet With
Induction tester Induction Sensor
96
7.1 Ensure that Qualified supervisor/ Engineer in-charges is available at site

7.2 Check that required material, equipment and accessories are available at site in
good condition.
7.3 Ensure Required PPEs are available at site in good condition
7.4 Ensure required screened workmen with gang leader available.
7.5 Ensure required P&M with Fitness Certificate by EHSO and nominated P&M in-
charge
7.6 Ensure availability of approved route survey drawing
7.7 Ensure availability of Route clearance from copy of concerned authority.
7.8 Ensure that required permits (PTP, Internal work permit, shutdown clearance
permit, daily work permit etc.) are available at site
7.9 Keep an effective communication system (Mobile/ Walkie-talkie etc.). If required,
7.10 Ensure availability of Emergency response plan

7.11 Ensure availability of First Aid Box
7.12 Ensure that PEP Talk is provided
7.13 If shutdown required, follow shutdown procedure
7.14 Climate information from meteorological department
EXCAVATION
Excavation in all kinds of soil:
1. Check for Existing underground Utilities using UG Utility Detector. Also does trial
pit to identify UG utility?
2. If UG Utility is detected, then reroute the same in consultation with client on
necessity.
3. Barricade the area as per the approved drawing providing min 1.5 m working
clearance with warning barricade and hard barricade depending on the site
condition. If required take permission for road diversion from concern authority.
97
4. Excavate the trench by manually /using machinery up to the 75 - 100 mm before
reaching required level.
5. Excavate the balance portion manually and remove loose materials on bottom of
the pits manually.
6. Do not over excavate the pit.
7. Keep the excavated earth at least 1.5 m /half of the depth of the pit away whichever
is more from the edge of the pit.
8. Provide a clear berm of a width of not less than one third the final depth of
excavation or as required by design. In case of space constraint it can be reduced
but not less than 1 m.
98
9. Provide toe board to prevent roll back of earth into the pit. Protect the periphery of
the stock pile by stacking bags filled with earth to prevent soil washout during rain
10. Remove surplus / unsuitable excavated soil from the working location
11. Provide safe access/egress by means of ladder or ramp
12. In case of rain, dewater the trench using dewatering pump.
13. Allow the people to enter the trench after inspection only if rain happen.
14. In case of firm soil, allow vertical cut upto 1.5 m, otherwise provide slope/do step
cut (1:4).
15. If space is not sufficient then, provide shoring and shuttering to restrict collapse of
side wall for depth more than 1.5 M
16. Provide shoring and shuttering in case of existence of nearby structure.
EXACAVTION IN ORDINARY/ HARD ROCK:
1. When hard rock is met with, carry out excavation using compressor/pneumatic drill
2. Give rest of 15 minute to operator after 30 minute of operation else ensure rotation
of operator after 30 minute gap.
3. Ensure that vibration absorbing pad is provided on handles of equipment .
4. Ensure that handle of compressor/pneumatic drill is not touch with the other parts
of body.
5. Allow only competent operator for operation of compressor/pneumatic drill
EXACAVTION IN WATER MUD OR FOUL POSITION:
1. Pumped out or remove water that may accumulate in excavation during the
progress of the work from springs, seepage, broken water main or drains
2. Make sure that pumping is done in such a way as not to cause damage to the work
or adjoining property by subsidence.
3. Ensure shoring and shuttering to prevent slipping/collapse.
99
CABLE LAYING:
1. Fill the fine sand up to required height (as per specification/approved drawing).
Ensure uniform level of sand throughout the trench.
2. Shift the cable drums as per the supplier specifications/manuals to site & mobilize
the required men and material/machinery for the cable laying.
3. Remove the wooden planks carefully so that nails do not get stuck with worker and
cable. Examine the cable IR value to cross check insulation damage.
4. Place the drum as marked to lay the cable / roll the drum on the cable jack. Ensure
that cable drum is rotated in such a way , so that cable come out from top of the
drum
5. Make sure that the jack is stable & placed on firmed ground. Don’t allow any body
to stand in front of the cable drum.
6. Place the cable rollers (horizontal and corner type) in trench as per supplier’s
specifications (see figure ow).
100
7. Place the winch at the other end of the cable drum.
8. Lay the Winch wire rope on the rollers, place the tension meter in between the cable
and wire rope and then connect properly to the cable end. Apply the specified
pulling torque (maximum allowable limit 2.5 Ton).
9. Remove cable rollers after completion of laying and place the cable in trench.
Continue the same procedure for each run of the cable. Ensure that the spacing
between each run of the cable should be identical and as per specification.
10. Maintain minimum bending radius as per the manufacturer instructions
11. In locations such as road crossing, paved areas etc. lay the cables in pipes or
closed ducts.
12. After completion of individual run ,check the IR value and then seal both end by
suitable cable sleeve/ end cap
13. Bury the Cables up to require height. At required height from the trench base, the
horizontal precast concrete slabs/bricks are to be used to fully cover the sand buried
cable as per specifications/approved drawing
14. Warning tape to be provided at required depth from ground level as per specification
and approved drawing
15. Now the backfill the trench with soil/earth
16. Provide Route markers as per specification.
101
9.1 If any structure is disturbed then, restore the same as it was.
9.2 Check that Tools and tackles, machineries and PPEs are brought back in good condition.
9.3 Backfill and compact the excavated soil that day itself.
9.4 All the Barricades/safety cones/fire extinguishers/shoring/shuttering are brought
back in good condition
10. RECORD
10.1 Insulation Resistance (IR) value Test format
10.2 Permit to work
10.3 Internal work permit cum shutdown line clearance
10.4 PTP
10.5 PEP Talk
10.6 Excavation Clearance permit
10.7 Excavation checklist
10.8 Cable drum card
11. DISTRIBUITION

Supervisors/Surveyor
102
f

Safe Operating Procedure: Horizontal
Directional Drilling (HDD) Work
1. PURPOSE:
To provide Operating Procedure for horizontal directional drilling activity to be executed
in a safe manner
2. SCOPE:
It covers the safe operating procedure for horizontal directional drilling for laying of all
types of cables at the project site
3.3 Approved shutdown procedure, if required
3.4 Technical Specifications
3.5 Approved survey report and drawing
3.6 Route clearance copy from concerned authority (Municipality, Electricity board,
Telephone agency, gas transmission authority, Water distribution authority etc.)
3.7 IS -1255 code of practice for installation and maintenance of power cables up to
and including 33 kV rating
3.8 Manufacturer test certificate/operating procedure for Cable Jack , Shaft,
Horizontal Directional Drilling (HDD) Machine and Winch Machine 3.10 Climate
information from meteorological department
4. RESPONSIBILITY:
Section In Charge, Site engineer, Site qualified field supervisor of BEL PT&D IC.

5.1 Horizontal Directional Drilling Rig,
5.2 Drill pipe, Drill bits and reamers
5.3 Drilling fluid mixing tanks,
5.4 Holding tanks,
5.5 Cleaning systems,
5.6 Recirculation containment collection and disposal etc. Road Meter
5.7 Tools or equipment for digging.
5.8 Warning Tapes
5.9 Spade
5.10 Shovel
5.11 Insulated Crow bar
103
5.14 Barricading tape/net
5.15 Hard barricade with retro reflective sticker
5.16 LED light (chain light)
5.17 DG operated light mast

5.18 Warning board/diversion board
5.19 Safety Cone
5.20 Pump for dewatering
5.21 Shoring /shuttering if required
5.22 Excavator
5.23 Trailer/truck
5.24 Red Flag/Blinking light
5.25 Underground utility detector
5.26 PP Rope
Helmet With
Induction Sensor
Induction tester
104
7.1 Ensure that Qualified supervisor/ Engineer in-charges is available at site
7.2 Check that required material, equipment and accessories are available at site in
good condition.
7.3 Ensure Required PPEs are available at site in good condition 7.4 Ensure
required screened workmen with gang leader available.
7.5 Ensure required P&M with Fitness Certificate by EHSO and nominated P & M
in-charge
7.6 Ensure availability of approved route survey drawing and data
7.7 Ensure availability of Route clearance from copy of concerned authority.
7.8 Ensure that required permits (PTP, Internal work permit, shutdown clearance
permit, daily work permit etc.) are available at site
7.9 Keep an effective communication system (mobile/ Walkie-talkie etc.). If required,
7.10 Ensure availability of Emergency response plan
7.11 Ensure availability of First Aid Box
7.12 Ensure that PEP Talk is provided

7.13 Collect Climate information from meteorological department
7.14 Based on surveyors’ data, drilling manager will make a bore plan and profile using
Atlas Bore planning computer software.
8.1 Prepare all drilling pits prior to the drilling team’s arrival as per the following
excavation procedure
8.2 Check for Existing underground Utilities using UG Utility Detector. Also does trial
pit to identify UG utility?
8.3 If UG Utility is detected, then reroute the same in consultation with client on
necessity.
105
8.4 Barricade the area as per the approved drawing providing min 1.5 m working
clearance with warning barricade and hard barricade depending on the site
condition. If required take permission for road diversion from concern authority.
8.5 Excavate the trench by manually /using machinery up to the 75 - 100 mm before
reaching required level. Use insulated hand tools for excavation.
8.6 Excavate the balance portion manually and remove loose materials on bottom of
the pits manually.
8.7 Do not over excavate the pit.
8.8 Keep the excavated earth at least 1.5 m /half of the depth of the pit away
whichever is more from the edge of the pit.
8.9 Provide a clear berm of a width of not less than one third the final depth of
excavation or as required by design. In case of space constraint it can be reduced
but not less than 1 m.
8.10 Provide toe board to prevent roll back of earth into the pit. Protect the periphery
of the stock pile by stacking bags filled with earth to prevent soil washout during
rain
8.11 Remove surplus / unsuitable excavated soil from the working location
8.12 Provide safe access/egress by means of ladder or ramp

8.13 HDD (Horizontal directional drilling) machine should be placed on level surface
and during operation the access area should be kept clear.
106
8.14 In case of rain, dewater the trench using dewatering pump.
8.15 Allow the people to enter the trench after inspection only if rain happen.
8.16 In case of firm soil, allow vertical cut upto 1.5 m, otherwise provide slope/do step
cut (1:4).
8.17 If space is not sufficient then, provide shoring and shuttering to restrict collapse
of side wall
8.18 When hard rock is met with, carry out excavation using compressor/pneumatic
drill
8.19 Give rest of 15 Minute to operator after 30 Minute of operation else ensure
rotation of operator after 30 Minute gap.
8.20 Ensure that vibration absorbing hand glove is used by operator.
8.21 Ensure that handle of compressor/pneumatic drill is not touch with the other parts
of body.
8.22 Allow only competent operator for operation of compressor/pneumatic drill
8.23 Pumped out or remove water that may accumulate in excavation during the
progress of the work from springs, seepage, broken water main or drains
8.24 Make sure that pumping is done in such a way as not to cause damage to the
work or adjoining property by subsidence.
8.25 Ensure shoring and shuttering to prevent slipping/collapse of nearby structure.
8.26 Based on surveyors’ data, make a bore plan and profile using Atlas Bore planning
computer software.
8.27 Establish the entrance and exit angles and the radius of the pipe curvature, to
achieve the depth and length of the drill.
8.28 If any utility is found then incorporate the necessary deviation in bore plan to
avoid any contact with the utility.
8.29 Construct all the water access to the entrance and exit sites for the HDD
operations
8.30 Prepare a level hard standing area for the drilling equipment at each of entrance
and exit sites.
8.31 For exit / rig side, prepare a rectangular area; the hard stand should be either of
clay filling with a cover of laterite, wooden mats or steel plates.
107
8.32 Barricade the area keeping safe distance from the exit point as the drilling fluid
pressure may be relieved and having potential hazard of striking nearby
personnel.
8.33 Ensure effective communication with drilling machine operator and the signal
man at the exit point
8.34 Ensure availability of sufficient water
8.35 Make sure that the pits excavated for pipeline exit and entry points are of
sufficient capacity to accommodate the used slurry / cutting mixtures.
8.36 For entrance side, construct hard stand in a similar manner to the exit side.
8.37 Construct a slurry pit to collect any bentonite / slurry discharged from the drill
hole.
8.38 Seal place stakes at the pipeline exit and entry points.
8.39 Place directional drilling unit at the entry where the drill will enter. Make sure that
it is placed on firm ground and anchored at four side to restrict displacement.
8.40 Ensure earthing of directional drilling machine.
8.41 Check for any leakage of hydraulic oil/drilling fluid at hoses and connectors Carry
out periodical maintenance of hydraulic oil / drilling fluid hoses and connectors
8.42 Before inserting or removing individual drill rods from the drill string, relieve the
drilling fluid pressure at the rig to avoid high velocity fluid squirting from the joint.
8.43 Verify the reduced drilling fluid pressure level by the corresponding pressure
gauge before disconnecting any rod
8.44 Provide guard to restrict touching of any rotating parts of the machine.
8.45 Wear tight clothing, insulated footwear, hand gloves, goggles, safety helmet,
reflective jacket
8.46 Elevate Drill unit at the rear so that the entrance angle conforms to the drill profile
drawing. Anchor Rig in position.
8.47 Start drilling operation by drilling a pilot hole using the drill bit, and the drill head
and the pressure injection of drilling fluid.
8.48 Continuously carry out Drilling in intervals of 3 meters (equivalent to one length
of drill pipe).
8.49 Maintain the depth / profile of the Drill from the ground level as per specification
/drawing.
8.50 Monitor location of drill pipe using DCI (Digital Control Indicator) locating system.
8.51 Once the drill bit exits the other end of the drill hole, relieve the system pressure
8.52 Remove the drill bead and attach reamer to the drill string depending of the
diameter of pipe to be installed. Pull back the reamer and make sure that the
required diameter is achieved for placing the pipe.

9.1 If any structure is disturbed then, restore the same as it was.
9.2 Check that Tools & tackles, machineries and PPEs are brought back in good
condition
108
9.3 All the Barricades/safety cones/fire extinguishers/shoring/shuttering are brought
back in good condition
10.1 Permit to work
10.2 Internal work permit cum shutdown line clearance
10.3 Pre Task Plan
10.4 PEP Talk
10.5 Excavation Clearance permit
10.6 Excavation checklist
11. DISTRIBUITION
Supervisors/drill opera
109
f

Distribution Transformer
1. PURPOSE:
This is to provide operating procedure for Installation of Distribution Transformer.
2. SCOPE:
It covers the safe operating procedure for the Installation of Distribution Transformer,

Handling and loading of Distribution Plain land/Hilly area/Forest Rating of transformer (10KVA/
transformer at store area/Desert area 16KVA/ 25KVA/ 63KVA/
100KVA/ 250KVA/
400KVA/500KVA/630Kkva/1M
VA)
Shifting of transformer by vehicle on Plain land/Hilly area/Forest
road area
Installation by chain pulley block or Plain land/Hilly area/Forest /
new generation crane or truck Desert area
mounted crane
Alignment and final Plain land/Hilly area/Forest
fixing of Transformer area/ Desert area
3.1 Contract Technical Specifications/ Rural Electrification Corporation Limited

(REC) Guide line
3.3 Approved Shutdown permit
3.6 Manufacturer Installation and Operation manual
3.7 Approved Structural and accessories fixing drawing
3.8 Approved GTP (Guaranteed Technical Particulars)
4. RESPONSIBILITY:
Section In-Charge, Site engineer, Site qualified field supervisor and sub-

110
5.2 Chain pulley block or new generation crane/ truck mounted
crane/Trailor/Truck
5.3 Wire rope/t sling (Size)considering DT weight
5.4 D-shackle
5.6 Screw Driver
5.7 Cutting Plier
5.8 FRP Ladder
5.9 Electrician tool kits
5.10 Measurement tape.
5.11 HV tester
5.12 Temporary earthing spike
5.13 Safety cone
5.14 Warning tape/net
5.15 Caution Board 5.16 LOTO system.
Helmet With Induction tester

Induction
Sensor

7.1 Screened and trained supervisor and workmen gang shall be available for
execution of work.
7.2 Ensure required tools for execution of work.
7.4 Approved Drawings shall be available at the location
7.5 All work permits (Daily work permit, shut down permit etc.) obtained before
stating of work.
111
7.6 Ensure valid fitness certificates by EHSO/P&M I/C of Derrick pole, new
generation hydra crane/ truck mounted crane, trailor / truck, chain pulley
block and tools and tackle.
7.7 Ensure valid driving license of driver of vehicles and crane operators.
7.8 Ensure physical verification of DT for any damages.
7.9 First Aid Kit
7.10 PPE and other safety gadget required: Safety Shoe, Safety helmet,
Induction tester, HV tester, full body harness safety t, hand gloves, reflective
jacket.
8.1 Handling and loading of Distribution transformer at store:

8.1.1 By Tripod Pole:
8.1.1.a Check the physical condition of tripod pole to ensure that the pole is safe
for use.
8.1.1.b Ensure availability of signal man along with the vehicle and reverse horn
and light of the vehicle.
8.1.1.c Do not allow any person to stand in between the vehicle and material.
8.1.1.d Fix the wire rope /t sling (size of sling to be considered with respect to
DT weight) on the lifting hook of transformer.
8.1.1.e Lift the transformer by means of chain pulley block.
8.1.1.f Do not allow any person to stand ow the lifted transformer.
8.1.1.g Place the vehicle ow the transformer with help of signal man.
8.1.1.h Lower the transformer to place on the trailer/truck/trolley and tie the
transformer with it required size of PP rope/Ratchet t.
8.1.1.i Place additional stopper.
8.1.2 By new generation hydra crane/ truck mounted crane:
8.1.2.a Check the crane physically to ensure the carne is safe for use.
8.1.2.b Place the hydra crane or out rigs of Truck Mounted Crane (TMC) on firm
ground.
8.1.2.c Fix the wire rope/t sling (required Size) on the lifting hook of transformer
and tie the tag line.
8.1.2.d Barricade the swing area of crane.
8.1.2.e Lift the transformer by means of crane and place on trailor /truck /trolley.
8.1.2.f Tie the transformer with trailor/truck/trolley.by required size of PP rope
and Ratchet t
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8.1.3 During lifting and handling material manually follow the ow
mentioned steps:
8.1.3.a Keep the back straight.
8.1.3.b Grip the material tightly.
8.1.3.c Hold the material close to the body.
8.1.3.d Use body weight while lifting material.
8.1.3.e Keep chin up right.
8.1.4 Shifting of transformer by vehicle on road:
8.1.4.a Use ratchet t to secure the transformer on truck.
8.1.4.b Do not allow any worker to travel along with transformer on the rear side
of vehicle.
8.1.4.c Don’t allow driver to drink and drive.
8.1.4.d Follow the road traffic rules (Speed limit) while drive.
8.1.4.e While reversing use reverse horn, reverse light and signal man.
8.1.4.f If required, stop the vehicle besides the road at the time of adverse
8.1.4.g Put wheel stopper while the vehicle is in rest.
8.2 Installation of transformer:

8.2.1 By chain pulley block:
8.2.1.a Place the vehicle nearest location of pole /Plinth with help of signal man.
8.2.1.b Do not allow any worker in between vehicle and pole.
8.2.1.c Put wheel stopper and barricade the working area.
8.2.1.d Place the FRP ladder on the pole to climb on pole.
8.2.1.e Only skilled worker having valid height pass climb on pole wearing full
body harness safety t.
8.2.1.f After reaching at height, anchor hook of full body harness.
8.2.1.g Fix the chain pulley block on structure with the help of wire rope sling.
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8.2.1.h Fix the sling on the lifting hook of transformer and tie the tag line.
8.2.1.i Lift the transformer and remove the vehicle with the help of signal man.
8.2.1.j Ensure that bushing of transformer do not come in contact with any
structure.
8.2.1.k Place the transformer on transformer resting base channel by means of
tag line.
8.2.2 By new generation crane/ truck mounted crane:

8.2.2.a Place the vehicle nearest location of pole/plinth with help of signal man.
8.2.2.b Do not allow any worker in between vehicle and pole.
8.2.2.c Put wheel stopper and barricade the working area.
8.2.2.d Place the crane or out rigs of crane on firm ground.
8.2.2.e Do not allow any worker in the swing area of the hydra crane.
8.2.2.f Fix the wire rope sling on the lifting hook of the transformer and tie the
tag line.
8.2.2.g Use slings and lifting tools of lifting capacity more than the weight of the
DTR
8.2.2.h Barricade the working area to prevent unauthorized entry.
8.2.2.i Let only signal man/rigger will give the signal to the operator.
8.2.2.j Lift the transformer and place it on transformer resting structure/ base
channel
8.3 Alignment and final fixing of transformer:

8.3.1 Use PP rope or tools bags for carrying and lifting tools and tackles at height.
8.3.2 Use PP rope for lifting structural material at height.
8.3.3 Do not allow anyone to stand ow the height work place.
8.3.4 Check the alignment of transformer and fix it on transformer resting
structure/base channel with the help of nuts and bolts/by welding stoppers
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9. POST OPERATION CHECK:
9.1 Ensure usage of materials as per approved drawings only to avoid redo of
work
9.2 Alignment of transformer and structure.
9.3 Tightness of nuts & bolts.
9.4 Removal of all loose material from height.
9.6 Re instating all disturbed utilities/structures.
10.1 Pre task Plan

10.2 PEP talk
10.5 Check list for Distribution Transformer Installation.
11. DISTRIBUITION
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f

Safe Operating Procedure: Service
Connection, Meter Fixing & Replacement
of Meter
1. PURPOSE:
This is to provide documented Operating procedure for Installation of Service Connection
both for ow Poverty Line (BPL) and Above Poverty Line (APL) and Meter Replacement
activities in a safe manner.
2. SCOPE:
It covers the safe operating procedure for installation of 1-ph Energy Meter, Service
Cable, Service Angle / GI bend pipe, GI Wire, Reel Insulator, D-Clamp with insulator as
mentioned ow, to be followed by BEL Employees, Subcontractors, Supervisors and
Workmen working at PT&D Sites:
3.1 Technical Specifications/ Rural Electrification Corporation Limited (REC) Guide
Line
3.3 Approved Work Order from Client for installation of 1 ph energy meter.
4. RESPONSIBILITY:
Section In-Charge, Site engineer, Site qualified field supervisor and sub-contractor
of PT&D IC .

5.1 Portable drill machine.
5.3 Screw Driver
5.4 Cutting Plier
5.5 Ladder
5.6 Line tester
5.7 PPE
5.8 Lock and tag
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Helmet With
Induction
Induction Sensor
tester
7.1 Ensure availability of approved Pre Task plan at location if required.

7.2 Ensure availability of approved Survey Drawing shall be available at the location
7.3 Inspect meter and accessories and ensure good condition materials are available
at the location
7.4 Take daily work permit and make sure that at working location
7.5 Give Pep talk on the activity to the working crew
7.6 Make sure that location specific emergency plan is available and briefed to the
crew leader, frontline supervisor
7.7 Make sure that Checklist for the procedure is available at the location with crew
leader, frontline supervisor and the engineer in charge.
7.8 Check for unauthorized activities like hooking. 7.9 Check Internal wiring at
consumer premises
7.10 Conduct Visual inspection of tapping pole.
7.11 Check Continuity and insulation of service cable.
7.12 Choose the nearest pole location for connection purpose.
7.13 Allow only screened workmen to complete the task.
7.14 Allow only the skilled workmen having height pass
8.1 SERVICE CONNECTION / METER FIXING
8.1.1 Collect authenticated List of connections for the ow poverty line (BPL)/ above
poverty line (APL) domestic consumers from clients.
8.1.2 Verify the consumers as per list and confirm in line with the procedure stipulated by the
client.
8.1.3 Check the condition Electrical Kits/Tools and tackles.
8.1.4 Decide the location for fixing of meter as per specification
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8.1.5 Make necessary drill on the wall for fixing of meter box and for fixing of short pole.
8.1.6 Be sure that portable drill machine is checked for its healthiness.
8.1.7 Fix Energy meter on the front wall at the height specified and switch board inside
the consumer house at appropriate location and height as specified in the
contract.
8.1.8 Fix the ladder to the wall of the household. Allow one person to hold the ladder
firmly. Make sure that ladder is placed on firm ground
8.1.9 Climb on the roof of the house using ladder. Anchor full body harness with fixed
structure if any, otherwise make arrangement scaffolding
8.1.10 Assess / Check strength of fragile roof/ house
8.1.11 Fix the BPL/APL pipe on the roof as per specification

8.1.12 Provide back stay with the BPL/APL pipe
8.1.13 Lay Service cable along with 10 SWG GI wire as pilot wire binded with reel
insulator from SMC/ DB / nearest LT pole to Short pole.
8.1.14 Lay Service cable from short pole to meter box with proper clamping on the wall.
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8.1.15 Make/Excavate the earth Pit of depth of 1.5 M as specified in the contract and at
a distance of
1.2 M from the house
8.1.16 Install the Earth electrode with chemical earthing /charcoal and salt /as per
specification of client
8.1.17 Connected to short pole with earth pit by using 8 SWG GI wire.
8.1.18 Fix the switchboard inside the consumer house at appropriate location, height
as per specification.
8.1.19 Do internal wiring to the single light point with rigid clamping system as per
contract specification.
8.1.20 Fix the CFL lamp to the light point with signature of the BPL holder for issuance
of CFL lamp.
8.1.21 Complete termination of service cable at meter and switch board and at light
point
8.1.22 Take shutdown as per the shutdown procedure, Check the pole condition before
climbing on it for its healthiness.
8.1.23 After shutdown, confirmation of shutdown must be checked by induction
tester/HV tester.
8.1.24 Fix the ladder to the nearest pole of the household where to install service
connection. Allow one person to hold the ladder firmly. Make sure that ladder is
placed on firm ground
8.1.25 Climb on the pole wearing safety helmet fitted with induction tester and full body
harness. Fix the harness with the pole
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8.1.26 Fix SMC DB on LT pole
8.1.27 Connect the service line with the LT SMC DB
8.1.28 Give Awareness about electrical safety to concerned BPL/APL family.
8.1.29 Charge the line as per the shutdown procedure
8.1.30 Maintain a register concerning all the details of service connection and update
daily basis.
APL SERVICE CONNECTION BPL SERVICE CONNECTION
8.2 PROCEDURE FOR METER REPLACEMENT:

8.2.1 Collect the approved details of meters to be replaced from client.
8.2.2 Prepare replacement schedule and take acceptance of client
8.2.3 Follow shutdown procedure
8.2.4 Use electrical tested rubber hand gloves during removing and connecting of service
line.
8.2.5 Ensure sufficient number of discharge rod fixed on electric line.
8.2.6 Verify the Meter Sl. No. Consumer identification No and consumer bill issued.
8.2.7 Note down the Consumer identification No, Existing meter Sl. No, Make and final
reading of the meter as per format given.
8.2.8 Disconnect the service connection
8.2.9 Remove existing meter
8.2.10 Fix new Energy meter on the switch board rigidly and terminate the service cable
from LT line and to load of consumer.
120
f

Safe Operating Procedure: Repair and
Maintenance Works
1. PURPOSE:
The purpose of this procedure is to provide safety guidelines to carryout Repair and
maintenance Activity in UPD project.
2. SCOPE:
The scope is to cover safe work procedure of R&M activity for UPD Jobs.
2.1 Renewal of earthing system.
2.2 To provide / replace damaged GOS.
2.3 To provide / replace damaged HG Fuse Unit /DOLO Cutout.
2.4 To provide / replace Failed/ damaged Lightning Arrestor.
2.5 To provide / replace damaged LT Wiring Kit.
2.6 Replacement of old or damage Distribution transformer and maintenance
3.1 Client approved structural drawings, Equipment drawings, Earthing drawing
3.2 Approved Survey Drawings or Initial inspection details.
3.3 Contract technical specifications.
3.4 Technical Specifications of R.E.C.
3.5 IE Rule. Electricity Act, 2014 and Electricity Rules, 2010
3.6 Approved PTP 3.7 BEL HSE Manual.
3.8 Project Quality Plan & FQAP
4. RESPONSIBILITY:
Responsibility of implementation of this Procedure lies Project Manager, Section In-
Charge, Site engineer, Site qualified field supervisor of PT&D IC.
5.1 Rope and pulley

5.2 Tool bag
5.3 Caution board
5.4 Lock & chain (for GOS)
5.5 First aid box.
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7. PRE-REQUISITE/ PRE-OPERATIONAL CHECK:
7.1 Pre shutdown survey details.
7.2 Work to be executed as per approved PTP
7.3 Required trained and skilled workmen.
7.4 Required PPEs for all the workmen.
7.5 Availability of all equipment & accessories
7.6 Availability of the good & all lifting tools required & inspection carried
8.1 DTC Earth Renewal:-
8.1.1 Check the work area prior to start the work to identify the back feeding
from any other sources and to understand the hazards recorded in the
PTP (in case of shut down jobs).
8.1.2 Take written shutdown from client for the system if required & followed
the SOP of Shutdown procedure for taking the shutdown.
8.1.3 Provide cone & caution tape around the work area to restrict the
movement of other persons.
8.1.4 Identify & ensure that no underground utilities are present in the
excavation work area.
8.1.5 Locate the 3 Nos. of Earth pit as per specification, ensure sufficient
clearance should be available for the nearby structures and it should
not be located inside the school premises, nearer to dust bin. The
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clearance for the earth pit to building structure should be maintained
as 1500mm. Earth pit to earth pit clearance also should be maintained
as per IE Rule/REC guideline. It should be either 6.5 M equidistance
or double the length of the earth electrode. Try to locate on triangle
formation, if not possible due to space constraint, maintain
equidistance.
8.1.6 Do the excavation for Earth pit. It should be min.600 dia and 2.8 M
Depth or as per specification.
8.1.7 Use insulated hand tools for any excavation.
8.1.8 Install the Pipe type Earth electrode/Chemical earth electrode/as per BOQ
earthing.
8.1.9 Identify the Earth pits as LA Earth pit, Neutral/Body earth pit 1&2
8.1.10 Ensure that LA earth pit should be nearer to the TC Structure pole.
8.1.11 Interconnect the Neutral/Body earth pit 1&2 with No.8SWG Earth wire.
8.1.12 Connect the DTC Neutral earth to the Neutral/Body earth pit 1&2 by two
distinct GUY Earth wire or as per specification, each wire should run
through each pole.
8.1.13 Connect the Lightning Arrestors to the LA Earth pit with two distinct
No.8SWG GI Earth wire, each wire should run through each pole and
it should be segregated either by alkathene tube or by PBC Pipe in
order to avoid contact with structural body and other earthing.
8.1.14 Run two distinct No.8SWG GI Earth wire from Neutral/Body Earth pit
1&2 to the poles
upto top. Connect all equipment to both side of earth wire on the pole.
All equipment’s should have the connectivity to both earth pit.
Equipment should be earthed are DTC Body, 3 Nos. HG Fuse unit, 3
Nos. of GOS units, LTP Kit/LTD Box, Meter protection box, GOS
handle with spiraled GI Wire.
8.2 Replacement of damaged GOS:-

8.2.3 Ensure the LC as per LC / Shut down format and Battery limit. Followed
8.2.4 Worker engaged in battery limit should be given clear instruction
about the battery limit & site supervisor must present all the time at
work location to ensure the minimum safe clearance is maintain all the
time & instruction of client is followed strictly.
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tester (Helmet mounted), Safety t & Safety shoes to all workmen.
8.2.6 Supervisor shall authorize the gang leader to start the work and indicate
to him the boundary limits within which the gang leader should work.
8.2.7 Dismantle the damaged / / faulty GOS, H-Frame, Ladder (as per PTP)
and install the new set.
8.2.8 Provide the jumpers with colour alkathene tube
8.2.9 Ensure the earthing provided for the GOS units and also the handle (Use GI
wire)
8.2.10 Align the GOS with petroleum gel for easy operation and proper closing.
8.2.11 Use FQAP checklist to ensure that all installation is done as required.
Ensure all workers & tools removed from work area before returning the
shout down.
8.2.12 Close the activity by ensure none of the tools left at top
8.2.13 Return the LC as per LC / Shut down format to the issuing authority.
8.3 Replacement of damaged HG Fuse Unit / DOLO Cut out:-


8.3.5 Ensure the availability of sufficient number of workmen for executing the
activity.
8.3.6 Ensure the LC as per LC / Shut down format and Battery limit.
tester (Helmet mounted), Safety t & Safety shoes to all workmen.
8.3.8 Use FRP Ladders to climb on structure for height work
8.3.9 Issue authorization to the gang leader to start the work by supervisor
and indicate to him the boundary limits within which the gang
members should work. Dismantle the damaged / faulty DO Fuse
Unit / DOLO Cutout and install the new set.
8.3.10 Ensure the earthing for HG Fuse Unit / DOLO Cutout
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8.3.12 Ensure all workers & tools removed from work area before returning the
shout down.
8.3.13 Close the activity by ensure none of the tools left at top
8.3.14 Return the LC as per LC / Shut down format to the issuing authority.
8.4 Replacement of Failed/Damaged Lightning Arrestor:-

activity.
8.4.6 Ensure the LC as per LC / Shut down format and Battery limit.
8.4.7 Provide all necessary PPE-Personal Protective Equipment like
Induction tester (Helmet mounted), Safety t & Safety shoes to all
workmen.
8.4.8 Use FRP Ladders to climb on structure for height work.
8.4.9 Issue authorisation to the gang leader to start the work by supervisor
and indicate to him the boundary limits within which the gang
members should work. Dismantle the Failed / Damaged Lightning
Arrestor and install the new set.
8.4.10 Provide the jumpers with colour alkathene tube
8.4.11 Ensure the two distinct earthing for Lightning Arrestor
8.4.13 Ensure all workers & tools removed from work area before returning the
shout down. 8.4.14 Close the activity by ensure none of the tools left at top
8.4.15 Return the LC as per LC / Shut down format.
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8.5 Replacement of Failed/Damaged/ Detoriarated LT Wiring Kit for DTC:-
8.5.6 Mark the Neutral and Street Light Phase and LT Phases (RYBN,
Street Light Phase) using colour insulation tape. If the colour
insulation tape not available the wires with No. of rings(R-1, Y-2, B-3,
N-4 and Street Light phase – 5 rings).
8.5.7 Dismantle the existing LT Wiring Kit from Distribution Transformer (DTC) to LT
Line.
8.5.8 Check the Position/Condition of LT Protection Kit and confirm/inform
the SO if requires additional/replacement of LTP Kit.
8.5.9 Relocate the LTP Kit as per our requirement / Mock up for dressing of cable.
8.5.10 Fix the SMC Meter box using correct size clamp, bolt & nuts.
8.5.11 Fix the Correct rating of Current Transformer (CT’s)
For DT’s CT Ratio to be used Cable to be used

Rating
15 / 25 kVA 50 / 5 A 50 mm2
50 / 63 KVA 100 / 5 A 95 mm2
100 KVA 150 / 5 A 120 mm2

200 / 250 KVA 400 / 5 A 240 mm2
500 KVA 800 / 5 A 240 mm2
8.5.12 Fix the Electronic Trivector Meter (ETV) Meter using all the bolts.
8.5.13 Fix the Dressing clamp / Fish plate for cable dressing on the Distribution
Transformer Center (DTC) structure Pole using correct clamps.
8.5.14 Draw the Cable from DTC to LT Protection kit through Sheet Moulding
Compound (SMC) Meter box using proper size of PVC Cable gland at
both ends without removing the rubber washer in the gland without
cutting the cable which leads wastage of cable.
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8.5.15 Dress the Cable neatly and fix it rigidly using PVC Spacers in such a way
that water should not enter into the metering compartment/CT
compartment.
8.5.16 Terminate the cable at DTC end using correct size Lug and crimping and
cover the bare area of conductor with Insulation tape that water should
not enter into the cable (i.e.
water should not enter in between cable and insulation).
8.5.17 Draw the cable from LTP Kit/ LTD Box to LT Line.
8.5.18 Dress the cable neatly and fix it rigidly using spacer.
8.5.19 Terminate the Cable with LT Line using correct size of PG Clamp.
8.5.20 Check the Tightness at all the places (DTC end, LTP Kit/LTD box end and
at LT Line). For cable support has to be taken by passing the cable
through NO.8 Strain and conductor.
8.5.21 Place the Internal Wiring kit and terminate the Wires.
8.5.22 CT Wires to be terminated and the sequence should not change.
8.5.23 Terminate the Platinum (PT) Wire to the cable by screwing the piercing clamp.
8.5.24 Terminate the CT & Potential wires at the meter end.
8.5.26 Ensure all workers & tools removed from work area before returning the shout
down
8.6 Replacement of old or damaged transformer & Maintenance:-

8.6.1 Check the work area prior to start the work to identify the back feeding from
any other sources and to understand the hazards recorded in the PTP
(in case of shut down jobs).
8.6.3 Ensure the LC as per LC / Shut down format and Battery limit. Followed the
SOP of Shutdown procedure for taking the shutdown.
8.6.4 Worker engaged in battery limit should be given clear instruction about the
battery limit & site supervisor must present all the time at work location
to ensure the minimum safe clearance is maintain all the time &
instruction of client is followed strictly.
8.6.6 Only skilled worker having valid height pass climb on pole wearing full body
harness safety t.
8.6.7 The weight of the old transformer to be assessed by the details of the
transformer.
8.6.8 The lifting arrangement should be selected based on the transformer weight.
8.6.9 Before removing the nut bolt of old transformer, fix the lifting
arrangement of old transformer & secure it with structure.
127
8.6.10 Do not allow anyone to stand ow the height work place.
8.6.11 Check the alignment of transformer and fix it on transformer resting
structure/base channel with the help of nuts & bolts/by welding
stoppers
8.6.12 SOP of the “Installation of distribution transformer” should be followed for
erection of new transformer
8.6.14 Ensure all workers & tools removed from work area before returning the shout
down

9.1 Ensure usage of materials as per approved drawings only to avoid redo of
work
9.3 Tightness of nuts & bolts.

10.1 PEP talk
10.2 Permit to work between supervisor, gang leader and worker.
10.3 Work permit.
10.4 PTP checklist.
10.5 Shutdown clearance (HT/LT) cum work permit for transmission line, APDRP/
Rural Electrification and other works
11. DISTRIBUTION
BEL PT&D -> Project Manager (PT&D), Section-In-Charge / Site Engineer/Site Supervisors.
128
f

Safe Operating Procedure: Substation
Civil Works
1. PURPOSE:
To provide documented operating procedure for executing the Substation Civil Work
activity in a safe manner.
2. SCOPE:
It covers the safe operating procedure for Substation Civil work activities and related sub
activities, to be followed by BEL Employees, Subcontractors, Supervisors and Workmen
working at PT&D Sites
3.4 Approved Pre Shutdown procedure
3.6 Approved procedure for execution of shut down work
3.7 Applicable CODES as per contract
3.8 Approved project EHS plan,
3.10 Field Quality Assurance Plan (FQAP)
4. RESPONSIBILITY:

5.1 Total Station.
5.2 Theodolite
5.4 Auto Level
5.5 Level staff
5.6 Mixer Machine
5.7 Scaffolding material
5.8 De watering pump
5.9 HD frames, wooden beam (DOKA)
129
5.10 Props
5.11 Steel wailers and wailer connectors
5.12 Timber runners
5.13 Plywood, nails and Form Release agent
5.14 Hammer ( 2kg ) with nail removing head,
5.15 hand wood cutting saw,
5.16 Plumb bob, line thread, right angle corner and water level tube or spirit level.
5.17 Hard Barricade, Warning barricade
5.18 Safety Cone
5.19 Fire Extinguisher
5.20 Safety Net
6. PERSONAL PROTECTIVE EQUIPMENT
Life Line
Retro
7. PRE-REQUISITE / PRE OPERATIONAL CHECK

7.3 Approved Survey Drawing shall be available at the location
130
7.4 Inspected Pole and accessories in good condition shall be available at the
location
7.8 Approved FQAP and Checklist for the procedure shall be available at the
location with crew leader, frontline supervisor and the engineer in charge.
7.9 Accepted installation checklist of Structure.
7.10 First Aid Kit in good condition.
7.11 PPE and other safety gadget required: Safety helmet, Safety Shoes, Hand
Gloves, reflective jacket, full body harness, helmet mounted induction tester.
Multi tester, Discharge rod and earth spike.
7.12 Screened and trained supervisor and screened qualified Workmen
7.13 Health check-up and Height pass for workmen to work at height
8.1 Survey of Topography
8.1. 1 In case of bushy areas clean the area first and use snake and Insect
repellent like Carbolic acid.
8.1. 2 In case of waterlogged area, dewater the area by using dewatering pump
8.1. 3 Use non-metallic level staff while doing survey inside an existing
substation to prevent the risk of electrocution.
8.1. 4 Marking of existing utilities such as cables, trenches, pipes etc. near to
excavation site to avoid any damage to existing structures during
excavation.
8.1. 5 Prepare diversion plan for the existing utilities and relocate the same if
required.
8.2 Excavation and Backfilling

8.2. 1 Make excavation area free from vegetation and any other obstruction
131
8.2. 2 Take the survey drawings to identify the location of excavation.
8.2. 3 Identify the Underground utilities using sample pits/UG utility detector
8.2. 4 Excavate the trial pit of width of 300 mm and depth of 1000mm around
the proposed layout to identify any buried cables or pipe lines etc.
8.2. 5 Do not allow workmen to wear loose cloths and chains.
8.2. 6 Keep Carbolic Acid/Bleaching Powder available at site.

8.2. 7 Use Insulated Crowbars for doing excavation, if there is any underground
electrical utility.
132
8.2. 8 Make Slope or shoring system if the depth of the excavation is exceeding
more than five feet.
8.3 During Excavation:

8.3. 1 Place the excavated soil 1.5 m/ half of the depth whichever is more away
from the edge of the excavated pit.
8.3. 2 Barricade the excavated pit for prevention of fall of person using hard
barricading
8.3. 3 Maintain minimum 3m distances from the existing live line and Dump
Truck that shifts the excavated material or backfilling material
8.3. 4 Move the Dump Truck that shifts the excavated material only after
lowering the hull to original position; Put the Caution Boards to caution
the outsiders.
8.4 Formwork.
8.4. 1 Fabricate the formwork as per formwork manufacturing system specification.

8.4. 2 Use horizontal life line along with Full body Safety Harness with
double Lanyard while working at height.
133
8.4. 3 Check the Fabricated formwork and transport to site for erection.
8.4. 4 Clean the Formwork surface and make free from any foreign
material or contaminants
8.4. 5 Apply form release agent on the formwork surface for a clean
release of the formwork.
8.4. 6 Fix Forms at site in position as per Approved drawings
8.4. 7 Place the Cover blocks on the reinforcement before placing the
forms for vertical members.
8.4. 8 Place the Inserts (Bolts, Plates) by tying them to the main rod or with
independent arrangement.
8.4. 9 Do not carry out welding to main reinforcement for supporting.

8.4. 10 Clean the shutters before placing the form work, and coat with form
releasing agent
8.5 Slab and Beam formwork

8.5. 1 Erect the tower with foot plate and tower spindle at bottom and tower spindle
at top
8.5. 2 Assemble the HD Tower independently at required spacing as per
scheme drawing and bracing at every 6m.
8.5. 3 Use Couplers and spring lock pins for connecting the frames.
8.5. 4 Place the props or frames on rigid ground. If loose earth is found,
the same shall be compacted before placing the forms.
8.5. 5 Place the props on a rigid surface like steel or timber plate.
8.5. 6 Provide necessary access platforms, stairs for easy access.
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8.5. 7 Use Green tag & red tag to identified safe and unsafe scaffolding.
8.6 Masonry and Plastering works

8.6. 1 Provide scaffolding such that it shall be carrying the load of workmen
and mortar box and dead load of bricks stocked.
8.6. 2 Use dust mask while handling cement.
8.6. 3 Keep the work place in good housekeeping before starting of work,
during work and immediately after completion of work.
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8.7 Concreting using mechanical mixer machines.
8.7. 1 Operate the mixer machine by authorized operator.
8.7. 2 Use ear protection while working near Mixer machines.
8.7. 3 Cover all the rotating parts (of Mixer machine)
8.7. 4 Make barricading around the skip bucket
8.7. 5 Inspect Daily the Mixer machine by the Operator.
8.7. 6 Weekly Maintenance by P&M Engineer.
8.7. 7 Monthly Joint inspection carried out by the EHSO / P&M
Engineer 8.7. 8 Make Provision of Tag line to control the
oscillations of Concrete bucket
8.7. 9 Provide Illumination of at least 53 Lux in practice.
8.7. 10 Vibrator cable routed must be away from the access and approach.
8.7. 11 For Electrically Powered Mixer Machine
8.7. 12 Use of Industrial type Plug top for the machine
8.7. 13 Route all connections through RCCB / RCBO
8.7. 14 Use Double insulated cable only
8.7. 15 Use Insulation tape for cable joints.
8.7. 16 Make no Cable joints Nearer to the machine.
8.7. 17 Provide main earth and Body earthing separately.
In normal circumstances where ambient temperature does not fall ow 15 C and where
ordinary Portland cement is used and adequate curing is done, following striking period
shall be adopted:
Minimum Period Before Striking Form

Type of Form work work
a) Vertical Form work to columns, walls, beams 16 – 24 Hours
b) Soffit form work to slabs (Props to be re-fixed 3 days

immediately after removal of form work)
136
c) Soffit form work to beams (Props to be re-fixed 7 days
immediately after removal of formwork)
d) Props to slabs:
1) Spanning up to 4.5 m 7 days
2) Spanning over 4.5 m 14 days
e) Props to beams and arches
1) Spanning up to 6m 14 days
2) Spanning over 6m 21 days

10. 1 Sketch of existing utilities and diversion plan.
10. 2 Level data
10. 3 Daily Work Permit
10. 4 Shutdown Line Clearance
10. 5 Permit required from concerned authority (UG Utility provider)
11. DISTRIBUTION
Supervisors
137
f

Mechanical Works
1. PURPOSE:
The purpose of this procedure is to provide safety guidelines to carry out mechanical
works in substation are to be executed in a safe manner.
2. SCOPE:
The scope is to cover safe work procedure of mechanical works in substation for Utility
Power Distribution Jobs, to be followed by BEL Employees, Subcontractors, Supervisors
and Workmen working at PT&D
Site.
2.1 Mechanical Material Handling
2.2 Structural Steel Erection.
2.3 Gas Cutting and welding.
2.4 Grinding.
2.5 Drilling.
3.2 3.2 PEP talk report Permit to work between supervisor, gang leader and
worker.
3.4 Weekly work permit.
3.5 Shutdown clearance (HT/LT) cum work permit for transmission line, APDRP/ Rural
Electrification and other works (
3.7 Hot work permit
4. RESPONSIBILITY:
Responsibility of implementation of this Procedure lies Project Manager, Section In-
Charge, Site engineer, Site qualified field supervisor of PT&D IC.
5.1 Rope and pulley

5.2 Tool bag
5.3 Caution board
5.4 Lock & chain (for GOS)
5.5 First aid box.
5.6 Welding machine
5.7 Gas cutting machine
5.8 Portable Grinding machine.
5.9 Portable drill machine.
138
5.10 Industrial boards and plug tops.
5.11 Double Insulated wires.
5.12 Fire Extinguishers with sand bucket.
5.13 Flash back arrestor.
5.14 Trolley
5.15 Insulated Electrode Holder.
7. PRE-REQUISITE/ PRE-OPERATIONAL CHECK:

7.1 Pre shutdown survey details.
7.2 Work to be executed as per approved Pre Task Plan
7.3 Required trained and skilled workmen.
7.4 Hot work permit.
7.5 Third party inspection certificate.
7.6 Required PPEs.
8.1 Mechanical Material Handling:-
8.1.1 Check the work area prior to start the work to identify any live line around work
area.
8.1.2 Prepare PTP and record the hazards in the PTP (in case of shut down jobs).
activity.
8.1.4 Follow proper shutdown procedure before executing of job.
8.1.5 Check the condition of lifting equipment before engaging in to execute
the job. The lifting equipment should be of good construction, made
from sound material, of adequate strength and free from faults.
139
8.1.6 Ensure the equipment must be tested and regularly examined to ensure its
integrity.
8.1.7 Ensure third party inspection of all lifting tools and tackles.
8.1.8 Check the condition of lifting tools and tackles before use. Do not use
if any damage observed.
8.1.9 Check the safe working load of all lifting tools and tackles.
8.1.10 Do not use broken, bird cage, core protrusion, Kink, Corrosion, surface
of wires worn by 1/3 or more of diameter wire ropes.
8.1.11 Safe Working Load (SWL) of wire rope= 8 x (Rope diameter in
inch)²Tonnes.
8.1.12 Lubricate wire rope at least once in a week.
8.1.13 In case of usage Bow shackle and D-Shackle-
i. Check for wear.
ii. Check for wear and straightness. iii.
Check that the pin is always seated.
iv. Check that the shackle is not opening up.
v. Do not replace shackle pin by bolts.
vi. Do not load the shackle above their lifting capacity which is embossed
on the shackle by manufacturer.
8.1.14 In case of eye bolts-
1. Do not apply angular loading on eyebolts.
2. Check eye bolt for wear.

3. Maintain the depth of 1.5 times the diameter of the bolt in tapped
hole for screwed eye bolts.
140
4. Do not insert hook directly to eye bolt.
8.1.15 In case of hook-

1. Use the hook as per correct capacity.
2. Check for wear and deformation.
3. Check for cracks and twisting.
4. Check for Wear and cracks.
5. Check for signs of “Opening up”. 6. Safety latch must be at
its place.
7. Maintain the hook in vertical position.

8. If the hook is eccentrically loaded, then safe working load will be
reduced.
9. No more than a 10 degree twist or 15% distortion of the opening
is allowable.
141
9.1.16 In case of use of cranes-
1. Engage only skilled, screened and trained manpower for the job.
2. Always do frequent and periodic inspection of cranes by
competent person.
3. Crane operator must have valid crane operating license.
4. Check for controls, mechanism, hooks and latches, running
cables, electrical
5. apparatus, safety devices, hydraulic system, tires, hydraulic
hoses.
6. Trained Signal man must be available during crane operation.
142
7. Do not overload crane beyond its safe working load. Load chart
must be displayed with safe working loads at different radii of
boom.
8. Display boom angle indicator on boom, if electronic display is
not provided in the operator cabin.
9. Ensure the availability of automatic device for cutting off power
to all motions, when boom exceeds safe angle limit.
10. Provide limit switch alarm to warn crane operator when safe
hoisting limit and maximum allowable boom angle limits are
reached.
11. Ensure that load must be secured before lifting.
12. Do not allow any person to stand ow suspended load.

13. Check all lifting tools and tackles before use and all must be third
party inspected.
14. Ensure outriggers of crane must be fully extended and placed at
leveled ground over sleepers.
15. Ensure the availability and working condition of horn, headlights,
side lamps, rear, spotlights and flashing directional indicators.
16. Maintain the proper C.G of the load during moving on leveled
ground, uphill & downhill position.
143
8.2 Structural Steel erection:-
8.2.1 Check the work area prior to start the work to identify any live line around work
area.
8.2.2 Prepare PTP and record the hazards in the PTP (in case of shut down jobs).
activity.
8.2.4 Follow proper shutdown procedure before executing of job.
8.2.5 Engage trained, skilled and screened workmen for the job.
8.2.6 Use wire rope slings with specially designed shackles for column
erection. The factor of safety of this shackle shall be of minimum 5.
8.2.7 Provide work platform and horizontal life line for carrying out de-slinging
and further structural works.
8.2.8 Carry out erection of beams, bracings etc. using the work platforms at
the top of each column.
8.2.9 Use tagline to control the movement of structural members during lifting
operation.
8.2.10 Provide lifeline for hooking of safety t while moving on the beam.
8.2.11 Secure tools which used at height so that they do not fall down.
8.2.12 Do not allow any employee or workmen to work directly under the
suspended load. Only workmen necessary for hooking or unhooking of
the load shall allowed.
8.3 Gas cutting and welding:- Gas Cutting-

8.3.1 Take hot work permit before starting of activity.
8.3.2 Remove the combustible materials around work area.
8.3.3 Wear protective clothing and eye protection before starting of job.
8.3.4 Blow pipe shall be shut off when not in use.
8.3.5 Clamp the work piece. Do not hold it in hand.
8.3.6 Keep hoses away from working area to prevent contact with flames,
heat, sparks or hot spatter.
8.3.7 Provide flashback arrestor on both cylinder and torch side.
8.3.8 Open the acetylene cylinder with the help of cylinder key to half a turn.
8.3.9 Adjust the regulator screw on acetylene regulator and oxygen regulator
to required pressure. In both the cases, cutogen valves on the torch are
closed.
8.3.10 Open the acetylene and oxygen cutogen valve, purge the hose and close
it.
8.3.11 Close the oxygen line valve on the torch and ignite the torch.
8.3.12 Adjust the oxygen to the required pressure.
8.3.13 While closing, close the oxygen cylinder and regulator then the acetylene
cylinder and regulator.
8.3.14 Close the oxygen torch valve then acetylene valve.
144
8.3.15 Use correct gas pressure and nozzle size.
8.3.16 To avoid backfire, blowpipe is not held too close to the work-piece and
clean the nozzle to avoid blockages.
8.3.17 Provide flashback arrestor at both ends of hoses to prevent backflow of
gas towards cylinders.
Welding activity-
8.3.18 Take hot work permit before starting of activity.
8.3.19 Remove combustible materials around work area.
8.3.20 Do periodic inspection of welding activity by competent person.
8.3.21 Engage only skilled, trained and screened welder for the job.
8.3.22 Check welding cables must be completely insulated, flexible type,
capable of handling the maximum current requirements of the work in
progress.
8.3.23 Attach the work lead (Welding lead) firmly to the work.
8.3.24 Work lead shall be as short as possible.
8.3.25 In case manual electrode holder, Use fully insulated electrode holder.
8.3.26 Ensure the cable shall be free from repair or splices upto a minimum
distance of 3.0 m from the electrode holder.
8.3.27 Return the welding current to welding machine by a single cable from
the work to welding machine.
8.3.28 Check all earth connections to determine that they are mechanically
strong and electrically adequate for the required current.
8.3.29 Develop a habit inside welder to always keep his body insulated from
work, metal electrode and holder.
8.3.30 Use necessary PPEs like safety shoes, gloves and apron.
8.3.31 Remove electrode from holder when not in use.
8.3.32 Arrange welding (secondary) terminals that no current carrying parts are
exposed to accidental contact.
8.3.33 Provide shade to protect welding machine in rainy condition.
8.3.34 Do not allow workmen for welding in wet, damp or humid conditions.
Because it reduces the skin resistance of the body and insulating
properties of accessories.
8.3.35 Arrange a cover for welder, equipment and work piece if there is a risk
of heavy rain.
8.3.36 Keep fire extinguishers, fire buckets with water nearby.
8.3.37 Provide good ventilation system during welding activity.
8.3.38 Provide Local Exhaust Ventilation if welding will carry out in confined
space.
8.4 Grinding:-
8.4.1 Engage only skilled, trained and screened workmen for the job.
145
8.4.2 Use only properly laed wheels. Read the markings and obey the
instructions for use.
8.4.3 Operating speed mentioned on the wheel shall be greater than the
spindle speed of the grinding machine.
8.4.4 Do not use grinding wheel after its expiry date.
8.4.5 Ensure that instructions on the wheel and on the machine are compatible.
8.4.6 Do not use damaged abrasive wheels.
8.4.7 Use wheels after completion of Ring test.
8.4.8 Ensure that wheel guard in position and securely fix before cutting off
or grinding operation.
8.4.9 No wheel shall be mounted on machine which is not intended.
8.4.10 Clean grinding wheel with brush and examined for any possible signs of
damage before mounting on machine.
8.4.11 Ensure that wheel revolves in opposite direction to the direction in which
the nut securing the wheel on the spindle is tightened.
8.4.12 Secure the work piece firmly before commencing grinding operation.
8.4.13 Use only dresses grinding wheel for grinding operation.
8.4.14 Do not use excessive force on grinding wheel during operation, it will
lead to wheel breakage.
8.4.15 Hold the wheel at an angle between 15° to 30°
8.4.16 Power supply of grinding machine must be routed through ELCB/RCCB.
8.4.17 Workmen must use necessary PPEs like face shield, ear muffs, dust
mask, gloves, apron, safety shoe, safety helmet.
8.5 Drilling :-
8.5.1 Select the bit or attachment suitable for the size of the drill and the work being
done.
8.5.2 Ensure that the bit or attachments are properly seated and tightened in the
chuck.
8.5.3 Keep drill air vents clear to maintain adequate ventilation.
146
8.5.4 Keep drill bits sharp always.
8.5.5 Keep all cords clear of the cutting area during use. Inspect for frays or
damage before each use.
8.5.6 Disconnect power supply before changing or adjusting bit or attachments.
8.5.7 Tighten the chuck securely. Remove chuck key before starting drill.
8.5.8 Secure workpiece being drilled to prevent movement.
8.5.9 Drill a small "pilot" hole before drilling large holes.

8.5.10 Do not drill with one hand while holding the material with the other.
8.5.11 Do not exceed the manufacturer's recommended maximum drilling
capacities.
8.5.12 Do not use High Speeds Steel (HSS) bits without cooling or using
lubrication.
8.5.13 Do not attempt to free a jammed bit by starting and stopping the drill.
Unplug the drill and then remove the bit from the workpiece.
8.5.14 Do not raise or lower the drill by its power cord.
8.5.15 Do not use excessive force to drill into hard material. Reduce drill speed
if possible.
9.6 Work
at
Height:-
9.6.1 Deploy only screened and trained person.

9.6.2 Check the availability of ladder, Safety t and fall arrester.
9.6.3 Position the ladder by maintaining required angle with the base (75
degree)
147
9.6.4 Deploy one person to hold the ladder
9.6.5 Wear the Safety t and other required PPE
9.6.6 Climb up the ladder by maintaining 3 point contact.
9.6.7 Anchor the harnesses of Safety t in such a way that always one
harness will be fixed with the rung of the ladder.
9.6.8 Always face the ladder during ascending / descending.
9.6.9 Check the suitability of the work platform / scaffold.
9.6.10 Anchor the both harnesses of Safety t with the hand rail of work
platform or horizontal lifeline after reaching the work platform.
9.6.11 Tie the hand tools with the hand by the rope.
9.6.12 Barricade the bottom area and don’t allow any person at that
position while working on height.
9.6.13 Don’t keep any loose material at height.
9.6.14 After completion of job remove all the loose and unwanted material from
height.
148
9.7 MAKING OF SCAFFOLD:-
9.7.1 Experienced gang to be deployed for making of Scaffold.

9.7.2 Safety t to be anchored during working at height at the time of making scaffold
9.7.3 No dissimilar material to be used during making of scaffold.

9.7.4 All tube and coupler scaffolding should be such designed that it can take 4 times
of the maximum intended loads.
9.7.5 All posts of scaffold should be accurately spaced and erected on suitable bases.
9.7.6 Scaffolding erection area shall be cordoned.
9.7.7 Scaffold tag system should be implemented (Red Tag for Unsafe Scaffold , Green
Tag for Safe Scaffold)
9.7.8 Ladder should be used for climbing up and down.

9.1 Visual inspection of lifting tools and tackles shall be done before starting of activity.
9.2 Work to be carried out by direct supervision.
9.3 Ensure PEP talk with DO’s and Don’ts before starting of activity.
9.4 Work to be carried out as per approved PTP.
9.5 Only authorized person shall be allowed for work.

10.1 PEP Talk
10.2 Permit to work between supervisor, gang leader and worker.
10.3 Hot Work permit.
10.4 PTP checklist
10.5 Shutdown clearance (HT/LT) cum work permit for transmission line, APDRP/
Rural Electrification and other works
11. DISTRIBUTION
BEL PT&D -> Project Manager (PT&D), Section-In-Charge / Site Engineer/Site Supervisors.
149
f

Testing & Commissioning
1. PURPOSE:
This is to provide operating procedure for testing and commissioning activity in
substation.
2. SCOPE:
It covers the safe operating procedure for testing and commissioning in substation.
2.1 Control and Relay Panels.
2.2 Power Transformers.
2.3 Station Transformer.
2.4 Current Transformers.
2.5 Potential Transformers.
2.6 Circuit Breaker.
2.7 Isolator / Earth Switch.
2.8 Lighting Arrestor.
2.9 Coupling Capacitor / Continuously variable transmission (CVT).
2.10 Alternating Current Distribution Board (ACDB).
2.11 Direct Current Distribution Board (DCDB)
3. 1 Contract Technical Specifications/ Rural Electrification Corporation Limited (REC). Guide

line
3. 2 Approved Shutdown permit
3. 3 Approved Pre Task Plan
3. 4 Project EHS
3.5 Manufacturer Installation and
Operation manual
3. 7 Approved drawing and layout.
3. 8 Approved Technical specifications.
3. 9 Approved GTP (Guaranteed Technical Particulars)
4. RESPONSIBILITY:
150
5.2 Digital Multimeter
5.3 Digital Megger
5.4 Galvanometer
5.5 Primary Injection Kit.
5.6 Screw Driver
5.7 Cutting Plier
5.8 Ladder
5.9 Electrician tool kits
5.10 Measurement tape.

5.11 Polarity tester
5.12 Knee point test kit
5.13 Leakage tester
5.14 Clamp tester
5.15 CRM kit
5.16 Timing test kit.
5.17 Hi Pot (High Potential) kit
5.18 TWRM kit
5.19 Relay test kit
5.20 Safety cone
5.21 Warning tape/net
5.22 Caution Board
5.23 LOTO system.
5.24 Industrial supply board and plug tops.
Ear
Dust mask Protection
151
Electric Electrical
insulated boot insulated
gloves
Induction Helmet With

tester Induction
Sensor
Retro

7.1 Screened and trained supervisor and workmen gang shall be available for
execution of work.
7.2 Ensure required tools and testing kit for execution of work and must be in
good condition.
7.4 Approved Drawings and layouts shall be available at the location
7.5 All work permits (Daily work permit, shut down permit etc.) obtained before
starting of work.
7.6 Ensure availability of calibrated instruments.
7.7 Ensure supply shall be routed through Residual Current Circuit Breaker
(RCCB) / Earth Leakage Circuit (ELCB).
7.8 First Aid Kit
7.9 PPE and other safety gadget required: Safety Shoe, Safety helmet,
Induction tester, High Voltage (HV) tester, full body harness safety t, hand
gloves, reflective jacket.
8.1 Carry out testing only under the supervision of qualified testing engineer.
8.2 Allow only skilled, trained and screened electrician for testing activity.
8.3 Barricade the testing area by using warning tape.
8.4 Do not allow unauthorized person inside testing area.
8.5 Do not arrange any temporary (hooking) supply for Testing. Use only A.C
Supply with extension board.
8.6 Provide MCB in the circuit of AC supply used for testing.
8.7 Ensure proper lighting arrangement at the testing area.
8.8 Check for all the electrical equipment/test kit is in good condition.
152
8.9 Ensure all men and materials, are removed and bus bar chambers are
closed.
8.10 Check the Calibration certificate of Test Kit.
8.11 Check the availability of insulating mat in front of Electrical Panel.
8.12 Ensure the Healthiness of the test leads (Check for any insulation
Damages).
8.13 Ensure proper earthing before meggering / high potential test.
8.14 Check the bus bar configuration in case a part of the panel is being
energized.
8.15 Ensure thorough checking before carrying out high potential test.
8.16 Ensure barriers provided panel manufacturers between bus bar chambers
must be in its place to avoid accidental contact.
8.17 Remove control circuit fuses before meggering and Hi Pot testing.
8.18 Use adequately insulated discharge rods with insulated wire for earth
connections for Discharging the de-energized line recognizing that
three types of voltages, ie. Static, Capacitive coupled and
electromagnetic induced voltage can exist in disconnected line.
8.19 Do not use rusted hardware for making connections.
8.20 Ensure that connections are tight and adequate contact area is provided.
8.21 Equipment is cleaned and free from dust / dirt, foreign materials etc.
8.22 Ensure visual inspection of equipment for any defects.
8.23 Check CT tank must be provided with double earthing.
8.24 Check that CT junction box is earthed.
8.25 Check Capacitive Voltage Transformer (CVT) / Potential Transformer (PT)
tank must be provided with double earthing.
8.26 Check that CVT / PT junction box is earthed.
8.27 Follow shutdown procedure if required.
8.28 Follow LOTO system after taking shutdown.
8.29 Use necessary PPEs.
9. POST OPERATION CHECK:

9.1 Ensure usage of materials as per approved drawings and layout only.
10.1 Pre task Plan

10.2 PEP talk
153
10.5 Check list for testing and commissioning.
11. DISTRIBUITION
154
f

Team members involved in SOP Preparation and Review:

Sl. Name Designation Cluster/Segment
155

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f

Power Distribution Business Unit

Sl. No. Description Page No.

0 Revision Control Sheet 3

2 Terms and Definitions 5-6

3 Tools and Equipment’s 7-15

4 Safe Operating Procedure for Pre Task Plan (PTP) 16-20

5 Safe Operating Procedure for Shutdown Procedure 21-31

6 Safe Operating Procedure for Survey 32-35

7 Safe Operating Procedure for Installation of Pole (Pole Shifting) 36-42

9 Safe Operating Procedure for Installation of Pole (Pole Erection) 50-57

10 Safe Operating Procedure for Structural Material Fitting 58-64

12 Safe Operating Procedure for Stringing of Conductor upto 33 kV 71-98

13 Safe Operating Procedure for Installation of AB cable 79-94

14 Safe Operating Procedure for Under Ground Cabling 95-102

16 Safe Operating Procedure for Installation of Distribution Transformer 110-115

17 Safe Operating Procedure for Service Connection, Meter Fixing &

19 Safe Operating Procedure for Substation Civil Works 129-137

20 Safe Operating Procedure for Substation Mechanical Works

21 Safe Operating Procedure for Substation Testing & Commissioning 150-154

BAJAJ ELECTRICALS LIMITED - POWER TRANSMISSION & DISTRIBUTION

REVISION CONTROL SHEET

Rev. No. Date Reason for Revision Approved By

BAJAJ ELECTRICALS LIMITED - POWER TRANSMISSION & DISTRIBUTION

BAJAJ ELECTRICALS LIMITED - POWER TRANSMISSION & DISTRIBUTION

TERMS AND DEFINITIONS

The document is split up to meet the above requirements as follows;

(As per the Indian Electricity Rules, 1956)

BAJAJ ELECTRICALS LIMITED - POWER TRANSMISSION & DISTRIBUTION

TOOLS AND EQUIPMENT’S

• The Safe Work Load (SWL) capacity of

• Ensure physical fitness of rope

• Ensure physical fitness of rope

• Ensure physical fitness of rope

• Ensure physical fitness of rope

Chain Pulley Block • Ensure physical fitness of Chain Pulley

Ratchet Leaching • Ensure physical fitness of webbing and

Crow Bar Insulated • Ensure physical condition

Post Hole Digging Tool (Buggi) • Ensure physical condition

• Ensure physical condition

FRP Ladder Ensure physical condition

Bamboo Scissors • Ensure good physical

Skidder (Channel) • 100 mm channel

Total Station Ensure calibration

Rodo Meter Ensure good condition

GPS with charger

• Pre engagement inspection of equipment.

• Pre engagement inspection of equipment.

• Pre engagement Inspection of equipment.

• Pre engagement Inspection of equipment.

• Good physical condition

Good physical condition

DG operated light mast • Good physical condition

Winch • Good physical condition

Distribution Transformer • Ensure required oil level

AB Switch • No damage in insulator

Lighting Arrestor Ensure good condition of

Parallel Groove Clamp. Suitable for the fittings

1.5 M length (1.2 M

Discharge Rod • No physical damage

Pen Tester • Good working condition

DOLO Fuse • No damage in insulator

Continuity Tester • Good working condition

Discharge Rod • No physical damage