Materials and Components

Materials and Components
AC POWER SUPPLY SYSTEM

Introduction:
Low voltage AC supply both single and three phases, is needed in a
substation for internal use for several auxiliaries.
Supply Source for Auxiliary AC System:
a) 415 V three phase supply from the distribution transformers.
b) Station transformers connected to the 11 kV or 33 kV station bus.
c) In case of main power Transformers, where tertiary winding is
available station Power supply can be availed with one auxiliary
Transformer
connected to the tertiary winding.
d) From the station transformer low voltage supply is extended to
the indoor AC Distribution panel through duplicate cables.
Duplicate feeds are given to important loads from the ac
distribution panels through outlets which are controlled by switch
fuses or MCBs.
e) In case of shutdown of entire substation Diesel Generator set
ensures AC
auxiliary supply for charging protective
equipments. Changeover scheme
shall be provided
in the AC distribution panel.
Auxiliary Low Voltage (LVAC) Supplies:
132kV or 220kV
POWER SUPPLY FROM

DIFFERENT SOURCE
11kV or
33kV
11/0.415kV
or
33/0.415kV
11kV or 33kV
400kVA
CONSUMER FEEDERS
INTERLOCK 2 OUT OF 3
400kVA
11/0.415kV
or
33/0.415kV
SUBSTATION AUXILIARY A.C SUPPLIES INCLUDING

FEEDS TO BATTERY CHARGERS
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The auxiliary AC system in a substation supplies to following electrical

auxiliaries
1. Illumination
2. Battery charging
3. Transformer cooling system
4. Oil Filtration plant
5. Transformer tap-changer drives
6. Air compressors
7. Power supplies for communication equipment
8. Crane
9. Breakers/ disconnect switch motors
10. Fire protection system
11. Space heaters in cubicles and Marshalling Kiosks
12. Air conditioning/Ventilation equipment.
Auxiliary system is at two or three A.C voltages such as 415V, 6.6 kV, 3.3
kV, and 11 kV.
Auxiliary AC system comprises the following:
Auxiliary step-down transformer in the substation

High voltage switchgear
LV AC switchgear
Load control centers
Power cables
A.C auxiliary distribution system
AC Distribution System:
This is made up of 415V load control centers and LV distribution system.
This system also shall have automatic load transfer system.
LT Transformers:
Ratings of LT Transformers:
i.
33/0.433 kV, 800, 630 & 250 kVA
ii.
11/0.433 kV, 630 & 250 kVA
Technical Requirements:
Core:
The core shall be constructed from high grade, non aging, and cold rolled
grain-oriented silicon steel laminations. The maximum flux density in
any part of the cores and yoke at normal voltage and frequency shall be
such that the flux density at any tap position with 10% voltage variation
from the voltage corresponding to the tap shall not exceed 1.9 wb/sq.m.
Windings:
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The conductor shall be of electrolytic copper, free from scales and burrs.
Insulating Oil:
The oil supplied with transformer shall be unused and have the
parameters for unused new oil conforming to IS: 335 while tested at oil
contractors premises. No inhibitors shall be used in oil. Ten percent
extra oil shall be supplied for topping up after commissioning in non
returnable containers suitable for outdoor storage.
Terminal Arrangement:
a. Bushing terminals shall be provided with suitable terminal
connectors of approved type and size for cable/overhead conductors
termination of HV side and cable termination on LV side.
b. The neutral terminals of 433 V winding shall be brought out on a
bushing along with the 433 volt phase terminals to form a 4 wire
system for the 415 volt. Additional neutral bushing shall also be
provided for earthing.
Off Circuit Tap Changing Equipment:
The tap change switch shall be three phase, hand operated for
simultaneous switching of similar taps on the three phases by operating
an external hand wheel.
Marshalling Box:
A metal enclosed, weather, vermin & dust proof marshalling box shall be
provided with each transformer to accommodate temperature indicators,
terminal blocks etc. It shall have a degree of protection of IP 55 as per
IS: 2147.
Cable Boxes:
Whenever cable connections are required, suitable cable boxes shall be
provided and shall be air insulated. They shall be of sufficient size to
accommodate Purchaser's cables and shall have suitable removable
side/top cover to facilitate cable termination and inspection. Cable boxes
shall be dust & vermin proof.
Fittings:
The following fittings shall be provided with each transformer
1 Conservator with drain plug and oil filling hole with blanking
plate
2 Plain oil Gauge
3 Silica gel Breather
4 Pressure Relief vent
5 Pocket on tank cover for Thermometer
6 Valves
7 Earthing Terminals
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8 Rating & Terminal Marking Plates

9 Lifting Lugs
10 Rollers
11 Air Release Plug
The fittings listed above are only indicative and any other fittings which
generally are required for satisfactory operation of transformer are
deemed to be included.
Technical Parameters:
Sl.
Description
No
a.
Type
Two winding
b.
Service
Outdoor
c.
Number of Phases
Three
d.
Frequency
50 Hz.
e.
f.
Type of cooling
Parameters
h.
Impedance at 750C with tolerance
ONAN
250 kVA, 630 kVA and
800 kVA
11/0.433 kV 33/o.433
kVA
0.05 10%
i.
Duty
Continuous
j.
Over load
Maximum Tem. Rise over 500C ambient
i. Oil (temp. rise measurement by
thermometer)
ii. Winding (temp. rise measured by
resistance method)
33 kV,
Windings
33 kV,
As per IS: 6600
Rating
Ratio
k.
l.
630kVA/
250 kVA
1.
1.
1.
2.
3.
System apparent
short circuit level (kA)
Winding connection
4.
5.
Insulator
6.
7.
t.
800kVA
Delta
Delta
11 kV,
630kVA/
250 kVA
0.433 kV
Delta
Star
Dyn 1
36
Uniform
52
11
70
95
28
170
250
75
--
36
52
12
--
Solid earthed
Tap Changer
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550C
As per IS: 2026 (Part-I)
Vector group
Insulation level l(kV)
a. Power frequency
test level (kV rms)
b. Basic impulse level
(kV peak)
Highest voltage (kV)
for each winding
Method of earthing
500C
0.433
1.
Tap range
+5%/-10% in steps of 2.5% on HV side
2.
Tap control
Off circuit tap
w.
HV Bushings
1.
Rated voltage, kV
2.
Rated current, kV
Basic impulse level
(kV)
Wet and dry power
frequency withstand
voltage (kV rms)
Minimum total
creepage distance
(mm)
Mounting
3.
4.
5.
6.
ee.
hh.
52
12
36
250
75
170
95
28
70
1300
300
900
100 A
Tank/Transformer body
LV and Neutral bushing

1. Rated Voltage (Volts)
1100
1100
1100
2. Rated Current (amps)
2000
1000
1000
Terminal Details
Suitable for 33 kV/11 kV
Cable
1. High Voltage
Low voltage phase
and neutral
Minimum Clearances
(mm)
in Air
2.
kk.
630 KVA
11 kV
33 kV
800 KVA
Cable box
33 kV,
630kVA/
250 kVA
33 kV,
800kVA
11 kV,
630kVA/
250 kVA
0.433 kV
1. Phase to phase
350
530
280
25
2. Phase to Earth
320
480
140
25
A.C Circuits:
Following are the A.C circuits present in a substation.
1. Auxiliary L.T Circuits
2.OLTC Control Circuits
Auxiliary L.T Circuits:

L.T Distribution Circuits to VCBs for Spring Charging motors, space
heaters and indications ( in some Breakers)
L.T Supply for Operation of OLTCs of Power Transformers
L.T Supply to Battery Charger
L.T Supply to Air Compressors
L.T Supply to Yard Lighting
L.T Supply for Sub Station Control Room, water Pumping etc.
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OLTC Control Circuits of Power Transformers:

Local (Electrical) tap changing circuit and Remote tap changing
circuit (Individual)
Simultaneous Remote tap changing circuit for Power Transformers

in
parallel (Master and follower circuits)
Example:
A typical example for A.C auxiliary system for a 220/33kV substation is
given below:
Diesel Generator Set:

Diesel generator set is one of the auxiliary systems present in a
substation. The diesel generator is provided in important substations and
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also in power stations to avoid complete blackout in case of system

failure.
DG set will be equipped with following equipment:
a) Diesel engine complete with all accessories
b) An alternator directly coupled to the engine through coupling
complete with all accessories.
c) Automatic voltage regulator
d) Complete starting arrangement, including two batteries and
chargers.
e) Base frame and foundation bolts.
f) Day tank of 990 litres capacity
g) Oil pump for transferring to day tank.
h) Engine cooling and lubrication system.
i) Engine air filtering system
j) Exhaust silencer package
k) Set of GI pipes, valves, strainers, unloading hose pipes as required
l) All lubricants, consumable ,touch up paints for filling, testing and
commissioning at site .The fuel oil for first commissioning will
also provided by the contractor.
m) AMF (Auto mains failure) panel for control, metering and alarm.
n) Acoustic insulation for DG set as per the norms of Central Pollution
Control Board.
System Design:
The diesel generator units shall be installed indoors. Suction of air

shall be from indoor and exhaust will be let out outside the
atmosphere, condensate traps shall be provided on the exhaust
pipe.
The fuel used shall be High Speed Diesel oil (HSD) or Light Diesel Oil
(LDO) as per IS: 460.
The diesel engines shall be directly water cooled. Cooling of water

through
Radiator and fan as envisaged.
The engine shall have closed loop lubricating system. No moving

parts shall require lubrication by hand prior to start of engine or
while it is in operation.
Control and Instrumentation:
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Each D.G set shall be provided with suitable

instruments, interlock and Protection and arrangement, suitable
annunciation and indications, for proper start up, control, monitoring
and safe operation of unit.
ii
The D.G set sets shall be provided with automatic

start facility to make it possible to take full load within 30seconds of
power supply failure.
iii
A three attempt starting facility using two impulse

timers and summation timer for engine shall be provided and if the
voltage fails to develop within 40sec.from receiving the first impulse,
the set shall block and alarm to this effect shall be provided in the
AMF panel.
iv
One local AMF control panel along with each D.G set
shall be provided. The AMF panel shall have IP-52 degree of
protection as per IS: 12063. Testing facility for automatic operation
of D.G set shall be provided in AMF panel
Following indication lamps shall be provided in the AMF panel:

a) Mains on
b) Alternator on
c) Charger ON/OFF
d) Breaker ON /OFF
e) Main LT supply ON/OFF
Following visual annunciations shall be provided in the panel for
Reasons for set shut down .
i.
Engine overheating
ii.
Low oil pressure
iii.
Lack of fuel
iv.
Set failed to start in 30 sec. after receiving the first start

impulse
v.
High cooling water temperature
vi.
Low level in daily service fuel tank
vii.
Over speed trip
viii.
Audio& visual Annunciation for alternator fault
The following accessories shall be provided in AMF panel.

i.
Frequency meter
ii.
3 nos. CTs for metering
iii.
3 nos. CTs for differential protection on neutral side
iv.
One DC Ammeter (0-40A)

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v.
One DC Volt meter(0-30V)
vi.
One Volt meter selection switch
vii.
One AC Voltmeter
viii.
Three timers (24V DC)
ix.
Two Auto /Manual selector switches
x.
Two Auto /Test /Manual selector switches
xi.
Eleven auxiliary contactors suitable for 24V DC
xii.
One motorized potentiometer for voltage adjustment
xiii.
Two sets of Battery chargers
xiv.
One set phase and neutral busbars
Technical Requirements:
A typical example giving technical requirements for DG set of a 400/220
kV substation is as follows:
1. Ratings: 250kVA, 1500RPM, 0.8pf, 415V, 3phase, 50Hz frequency.
2. DG sets shall be rated for 110% of full load for 1hour/day of
continuous running.
3. The output voltage, frequency and limits of variation from open
circuit to full load shall be as follows:
a) Voltage variation: +/-5% of the set value .Provision shall exist to
adjust the set value between 90% and 110% of nominal
generator voltage of 415V
b) Frequency 50Hz +/-2%
4. Type insulation but limited to class-B for temperature rise
consideration. The diesel generator and other auxiliary motor shall
have epoxy thermo setting
5. The day tank of 990 litre capacity shall be provided on suitably
fabricated steel platform. The tank shall be complete with level
indicator marked in liters, filling inlet with removable screen, an
outlet, a drain plug, an air vent, an air breather and necessary
piping. The tank shall be painted with oil resistant paint and shall be
erected with Indian Explosive Act of 1932.
6. Six output terminals shall be provided in alternator terminal box. The
neutral shall be formed in Auto Mains Failure (AMF) panel. The
generator terminal box shall be suitable to house necessary cables
and should be made of non-magnetic material.
7. For transferring oil to day tank transfer pumps are envisaged. The
capacity of transfer pump shall be adequate to fill the day tank in
about 30 minutes.
Operation of D.G Set:
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Standby DG set consists of a diesel engine coupled to an alternator. The

standby DG set has the Auto Mains Failure (AMF) sensing panel which
senses the failure of mains supply on input bus more than the set time
before starting of a D.G set. MCCB s 1 & 2 will be tripped off due to their
under-voltage coil being not energized because of absence of input A.C
power. Contactors in AMF panel will then close to restore power to
critical loads. Mains failure is sensed on both UPS-1 and UPS-2 input
buses and in case of these buses has mains failure, the DG will start and
supply power to that bus via either of the contactors. AMF panel makes
three successive attempts for starting the DG sets. DG set will be
inhibited from staring if AMF panel selector switch is in off position. When
primary power is restored and remains on for 1 to 10 minutes, the DG set
will be automatically switched off.
Following instruments shall be provided with diesel engine:
i.
ii.
iii.
iv.
v.
Lubricant oil pressure gauge

Lubricant oil temperature thermometers
Water temperature thermometers
Exhaust gas pyrometer with temperature switch
Engine meter
DG set shall be capable of being started /stopped from remote as well as

local manually. Remote START/ STOP push button shall be provided to
prevent shutting down operation as long as D.G circuit breaker is closed.
The diesel generator shall commence a shutdown sequence whenever
any of following conditions appears in the system:
i
ii
iii
iv
v
vi
vii
viii
ix
Over speed
Overload
High temperature of engine, cooling water and lubricating oil.
Low lubricating oil pressure.
Generator differential protection
Short circuit protection
Under voltage
Over voltage
Further interlocking of breaker shall be provided to prevent
parallel operation of DG set with normal stationary supply.
Tests:
The diesel generator set shall be tested for Routine and Acceptance tests
as per
relevant standards. The type test report for a diesel engine and
alternator are to be submitted by the supplier.
Commissioning Checks:
The following commissioning checks are to be carried out at site.
Load Test:
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The engine shall be given test run for a period of at least six hours. The
set shall be subjected to the maximum achievable load not exceeding
the specified D.G set rating. During the load test, half hourly readings of
the following shall be taken.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
Ambient temperature
Exhaust temperature if exhaust thermometer is fitted
Cooling water temperature
Lubricating oil temperature
Lubricating oil Pressure
Colour of exhaust gas
Speed
Voltage, Wattage and current output
Oil tank level
Insulation Resistance Test for Alternator: Insulation resistance

between the coils and the alternator frame shall be measure with 500V
Megger.
Check for Fuel Consumption: The check for fuel consumption shall be
made during the load run test.
Insulation Resistance of Wiring: Insulation resistance of control
panel wiring shall be checked by 500V Megger. The same shall not be
less than one mega ohm.
Functional Tests:
On control panel,
On starting provision on the engine,
On all field devices,
On AVR and speed governor.
Measurement of Vibration:
The vibration shall be measured at maximum achievable load and shall
not exceed 250 Microns.
Noise Level Check:
The noise level shall be measured (as per IS: 12065) when the D.G set is
operating at rated speed at maximum achievable load with a slow
response meter on the
A- weighting scale at a minimum of 8 points
all round DG set at a distance of one meter from the nearest surface of
the machine and at a height of 1.5 m from the floor level. The average
of A-weighted sound level measurement shall be expressed in decibels to
a reference of point 0.002 microbar.
Uninterruptible Power Supply (UPS):
Introduction: An Uninterruptible Power Supply (UPS) is a device
installed upstream of the equipment or the network which requires a
continuous source of electrical power, with a high level of reliability. UPS
systems are designed to filter out voltage transients and variations, and
assure continuous operation during primary power failures of variable
duration caused by lightning, short-circuit, etc.
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Functionality: The UPS consists of the following elements.

i Rectifier battery/charger
ii DC/AC inverter
iii Battery
iv Static switch for source commutation
v Isolating transformer
vi Mains by-pass switch
vii Maintenance by-pass switch
Only the first three components in the above list occur in all UPS. Others
may be installed depending on power, importance and type of load.
A UPS has the following modes of operation.
Normal Mode:
Load is supplied from the mains 1 via the rectifier and inverter. Battery is
being charged.
Autonomous Operation: Mains 1 power cut. Load is supplied from the
battery via the inverter.
By-pass Supply:
When Mains 1 power is cut due to overload or failure of the inverter. The
static switch changes over to the Mains 2.
Manual by-pass
Rectifier, charger and static switch are isolated. Maintenance of the UPS
is possible without any disruption for the supply.
UPS Operation Monitoring:
For the proper operation of the UPS several measurements, parameters
and alarms are monitored. They may vary according to the manufacturer
and type. The following lists of typical parameters are not exhaustive and
for a given type may be reduced or extended.
Measurements to be obtained:
a. Rectifier voltage/current
b. Inverter voltage/frequency
c. Load current
d. Mains 1 voltage
e. Mains 2 voltage
f. Battery voltage/current
Status to be indicated:
Position of all switches.
Alarms Provided:
i Inverter fault
ii Rectifier fault
iii Inverter current limitation
iv Mains 2 voltage/frequency out of limits
v Overcharge
vi Overheating
vii Battery voltage too high
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viiiEnd of battery autonomy
DC AUXILIARY SYSTEM
Introduction:
The most critical component of a Protection, Control and Monitoring
(PCM) system is the auxiliary DC control power system. Failure of the dc
control power can render fault detection devices unable to detect faults,
breakers unable to trip for faults, local and remote indication to become
inoperable. Capital cost and reliability objectives must be considered
before defining the D.C systems to be used for a specific installation.
a) Battery Unit:
A battery converts chemical energy I n to electrical energy by means of
an electrochemical oxidation-reduction reaction. This type of reaction
involves the transfer of electrons from one material to another through
an electric circuit. The basic electrochemical is called cell
Components of a battery cell:
A resilient plastic container
i.
The anode: This gives up electrons to the external circuit and is

oxidized during the electrochemical reaction it should be an efficient
reducing agent with high columbic output (Ah/g), good conductivity,
stability etc.
ii.
The Cathode: This accepts electrons from the external circuit and
is reduced during the electrochemical reaction it should be an efficient
oxidizing agent, stable when contact with electrolyte and have useful
working voltage.
iii.
Electrolyte: This provides the medium for transfer of electrons as

ions inside the cell between the electrodes. It must have good ionic
conductivity but not electrically conductive as it wound cause
electrical short-circuiting it should not react with the electrode
materials and shall be stable with temperature changes.
iv.
Plate separators: These made of porous synthetic material for

separating anode and cathode mechanically. They are permeable to
the electrolyte in order to maintain the desired ionic conductivity
v.
Lead terminals: These are for connecting the battery to the

external circuits. Both +ve and ve terminals of the cells shall be
capable of proper termination and shall ensure its consistency with
the life of the battery.
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vi.
Container: The container shall be fire retardant and shall have an

oxygen index of at least 28%.The porosity of the container shall be
such as not to allow any gases to escape except from the regulation
valve. The container material shall have chemical and electro
chemical compatibility and shall be acid resistant. Cell shall not show
any deformity or bulge on the sides under all working conditions.
vii.
Cell covers: The cell covers shall be made of suitable material

compatible with the container material and permanently fixed with
the container. Fixing of pressure regulation valve and terminal posts in
the cover shall be such that the seepage of electrolyte, gas escapes
and entry of electro static spark are prevented.
viii.
Pressure Regulation Valve: Each cell shall be provided with a

pressure regulation valve. The valve shall be self re-sealable and
flame retardant. The valve unit shall be such that it can not be
opened without proper tool.
ix.
Connectors, Nuts and Bolts, Heat Shrinkable Sleeves: Where

it is not possible to bolt the cell terminals directly to assemble a
battery, separate non corroding lead or copper connectors of suitable
size shall be provided to enable connection of the cells. Copper
connections shall be lead coated to withstand corrosion due to
sulphuric acid at a very high rate of charge or discharge. Nuts and
bolts for connecting the cells shall bee made of copper, brass or
stainless steel. Copper or brass nuts and bolts shall be lead coated to
prevent corrosion. Stainless steel bolts and nuts can be used without
lead coating. All inter cell connectors shall be protected with heat
shrinkable silicon sleeves for reducing
Batteries: Batteries consisting of individual cells are used to store

electricity and are relied
upon to provide the required power for a
specified period with in specified voltage limit.
Battery Capacity: The capacity of the battery is determined by the
capacity of the individual series Connected cells.
Types of Cells: The Battery cells are of two types.
1. Primary Cells
2. Secondary Cells
A primary cell is any kind of electrochemical cell in which the

electrochemical reaction of interest is not reversible, so used in
disposable batteries. The most common primary cells today are found in
alkaline batteries; earlier carbon-zinc cells, with a carbon post as cathode
and a zinc shell as anode were prevalent. Unlike a secondary cell,
attempting to reverse the reaction in a primary cell via recharging is
dangerous and can lead to a battery explosion. A related difference is
that primary batteries use up the materials in one or both of their
electrodes, while, ideally, the reversibility of the reactions in a secondary
cell allows them to be restored to almost the same fully charged
condition on each recharging.
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The battery unit consists of number of secondary cells (storage cells).

The Chemical reaction which takes place in a Lead Acid Storage Battery
is as follows.
Battery
Discharged
Battery Charged
(+Plate)
(-Plate)
PbSo4
2H2SO4
(-Plate)
PbSo4 + 2H 2O
(+Plate)
Lead Sulphate +Lead Sulphate+ Water
PbO 2 + Pb
Led Peroxide + Lead +

Sulphur
ic Acid
Types of Batteries:
1. Tubular Lead Acid Batteries
2. Plante Lead Acid Batteries
3. Valve Regulated Lead Acid(VRLA)Batteries
4. Flooded/Wet cell batteries :
5. AGM: Absorbed Glass Mat batteries
6. Gel cell batteries
7. Carbon foam leads acid batteries
8. The principle of the lead acid cell can be demonstrated with simple
sheet lead plates for the two electrodes. However such a
construction would only produce around an amp for roughly
postcard sized plates, and it would not produce such a current for
more than a few minutes.
Gaston Plante realized that a plate construction was required that gave
a much larger effective surface area. Plant's method of producing the
plates has been largely unchanged and is still used in stationary
applications.
Wet cells designed for deep discharge are commonly used in golf carts
and other battery electric vehicles, large backup power supplies for
telephone and computer centers and off-grid household electric power
systems.
Gel batteries are used in back-up power supplies for alarm and smaller
computer systems (particularly in uninterruptible power supplies) and for
electric scooters, electrified bicycles and marine applications. Unlike wet
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cells, gel cells are sealed, with pressure relief valves in case of
overcharging. In normal use they cannot spill liquid electrolyte.
Absorbed glass mat (AGM) cells are also sealed and used in battery
electric vehicles, as well as applications where there is a fairly high risk
of the battery being laid on its side or over-turned, such as motorcycles.
VRLA(Valve Regulated Lead Acid) Batteries: These batteries are
preferred for use in substations and power stations due to the following
advantages.
i
VRLA batteries have a pressure regulated valve which does not allow
the gasses to escape unless the set pressure is exceeded. As the
charging voltage is kept at lower level, there is negligible gassing.
Moreover, recombination of hydrogen and oxygen is achieved by,
which further results in reduction in loss of water. As the amount of
released gasses is negligible, release of acid fumes is also reduced.
Hence these batteries can also be installed in the equipment room.
Whereas, in flooded batteries (tubular/flat-pasted batteries) a large
amount of sulphuric acid fumes are released, due to which a separate
battery room with exhaust fans is essential.
ii Use of VRLA batteries results in:
Saving in space as the battery, power plant and equipment can

be installed in the same room.
Saving in bus-bar/cable material.
Low voltage drop resulting in better utilization of battery

capacity and increase in efficiency of equipment.
iii Charge efficiency of these batteries is excellent, i.e., 6 to 8 hours for

90% recovery, as against 12 to 14 hours for flooded batteries.
Recouping of capacity is quicker as shorter time is sufficient as
compared to flooded batteries, suiting the rural power supply
conditions particular
iv They have high charge density, resulting in smaller battery size.
Moreover, the battery can be discharged to lower end-cell voltage,
viz., and 1.75V/cell against 1.85V/cell for flooded batteries.
v
They can be stacked horizontally and the cell can be stacked one
above the other, which reduces the battery space requirement by 3060%.
vi They can be transported in the charged condition as there is no

danger of the spillage of the electrolyte, and hence, initial charging at
site is not required. Flooded batteries can not be transported in
charged condition, hence assembly and charging at site is essential.
Moreover, it will be more difficult for the flooded batteries to meet the
pollution norms, issued by Ministry of Environment and Forest.
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vii Capacity of VRLA batteries can be recovered even after a storage

period of six months/one year within three to four charge discharge
cycles, while in flooded batteries it very difficult even after one month,
due to sulphation of the plates while in idle condition.
viii Stratification is unavoidable in flooded batteries because of the
settling down of the acid in the lower portion of the cell which causes
sulphation in both lower and upper parts of the plates. To avoid
stratification, periodic boost-charging of these batteries at 2.7V/cell is
absolutely essential, for agitating the electrolyte.
ix In VRLA batteries, internal short-circuiting does not occur, while it is
quite common in flooded batteries due to sedimentation of shed
active material of the positive plate.
DC Circuits:
Following D.C circuits are present in a substation:
i
Control circuits
ii Indication and alarm circuits

iii Battery Charger, and D.C distribution circuits
i. Control Circuits:
a) Breaker Closing Circuits
Remote closing circuits
Local closing circuits
b) Breaker Tripping Circuits
Remote tripping circuits
Local tripping circuits
Relay tripping circuits
c) Interlock Circuits
Interlock between breakers and isolators
Interlock between breakers
ii. Indication and Alarm Circuits:

i. Breaker close indication circuit
ii. Breaker open indication circuit
iii. Healthy trip indication circuit
iv. Spring charge indication circuit
v. Semaphore circuit
vi. Breaker trip alarm circuit
vii. Over Current/Earth fault relay trip alarm
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viii.Transformer Alarm Circuits, Oil Temp High, winding Temp high,

Transformer Buchholtz, OLTC Buchholtz, Low oil level alarms
Distance Protection, differential.
Protection and various other
protection relays trip alarm.
iii. Battery Charger and DC Distribution Circuits:
Boost Charger Circuit
DC Leakage Circuit
Float Charger Circuit
DC Distribution Panel Circuit
DC Systems:
The DC System in the sub stations comprises of the following:
1. DC Charging System consisting of AC/DC Chargers
2. Battery Unit
3. DC Distribution System
Communication circuits:
1. Emergency lighting system
2. UPS-Uninterrupted power supply
3. PLCC (Power Line Carrier Communication) and
4. SCADA (Supervisory Control and Data Acquisition)
Auxiliary D.C Voltage Levels:
System Requirements:
System Voltage
Maximum
Voltage during
Float
operation
Min. Voltage When no

charger is working
and battery fully
discharged up to
1.85V per cell
220V
242 V
198 V
110V
121 V
99 V
48V
52.8V
43.2 V
a) DC Charging System:
Storage battery cells are charged to compensate their discharge so that
they are available for any emergency. The charging is done on
continuous basis to take care of load discharge or self discharge by the
battery there are mainly two types of charging used in the sub-stations.
162
Power Division
Normally the DC power is supplied to the load by the float charger. It

also supplies trickle current to the battery to keep it healthy. If the
charging current under float mode exceeds a set level, boost charger is
switched on. It supplies quick charging current to the battery. On battery
reaching the set value, the boost charger is switched off.
Float/boost chargers are must in power substations, generating stations,
telephone exchanges etc. For control/monitoring systems, tripping
circuits and supplying DC power source.
1. Float or Trickle Charging: Float charging is done to meet the
demand. When nominal voltage of the battery cell is 2.0 V there is
considerable variation during charging and discharging. For batteries
on float charge for continuous stand by duty floating voltage is to be
selected correctly. If this voltage is below 2.10V per cell, the cells will
gradually loose there charge due to internal losses and would require
frequent boost charging at 2.3 2.7V per cell to bring back to the fully
charged state. If the floating voltage is above 2.3V per cell there
would be excessive gassing and electrolyte level have to be made up
at more frequent interval levels. For Keeping the Battery fully
charged. With out requiring boost charging, Battery manufactures
recommend floating at 2.25V per cell. For allowing necessary safety
margin for voltage fluctuations, charger regulation, voltmeter error
etc. The optimum continuous bus voltage would be about 7% higher
than the nominal voltage of the DC system. It would be about 235Vfor
220V system. The number of cells would be 109 with 2.15V per cell.
Equalizing Charging: This consists of raising voltage above floating
voltage and maintaining it for specific time. To prevent batteries from
under charging and also to build up the specific gravity after
prolonged battery discharge equalizing charging is to be done to the
battery banks. This charges up the week cells before they become
sulphated and arrests any tendency of heavy acid to sink to the
bottom of the cell. It is recommended that equalizing charge shall be
given quarterly to all floating batteries.
2. Boost Charging: Boost charging is done as emergency charging for
the batteries which are in discharged condition. During boost
charging the battery charger shall operate on constant current mode
(when automatic regulator is in service) .It shall be possible to adjust
the boost charging current continuously over a range of 50 to 100% of
the rated output current for Boost charging mode. The charger output
voltage shall automatically go on rising, as the battery charges up. For
limiting the output voltage of the charger, a potentio meter shall be
provided on the front of the panel, where by it shall be possible to set
the upper limit of the voltage. Suitable filter circuits shall be provided
in all the chargers to limit the ripple content (peak to peak)in the
output voltage to 1%,irrespective of the DC load level, when they are
not connected to a battery.
163
Power Division
All battery chargers shall have two nos. MCCBs on the input side to
receive cables from two sources. Mechanical interlock should be provided
such that only one shall be closed at a time. It shall be of P2 duty and
suitable for continuous duty. MCCBs should have auxiliary contacts for
annunciation.
Rectifier Transformer: The rectifier Transformer shall be continuously
rated, dry air-cooled (A.N.) and of Class - F insulation type. The rating of
the rectified Transformer shall have 10% overload capacity.
Rectifier Assembly: The rectifier assembly shall be fully /half controlled
bridge type and shall be designed to meet the duty as required by the
respective charger. The rectifier shall be provided with heat sink having
their own heat dissipation arrangements with natural air cooling.
Necessary surge protection device and rectifier type fast acting HRC
fuses shall be provided in each arm of the rectifier connections
Instruments: One AC Volt meter and one AC ammeter along with
selector switches shall be provided for all chargers in the AC incoming
circuit.. One DC Volt meter and one DC ammeter (with shunt) shall be
provided for all chargers on DC out going circuit. The instruments shall
be flush type, dust proof and moisture resistant. The instruments shall
be of 1.5 accuracy classes. In addition to the above a centre zero
voltmeter with selector switch shall also be provided for 220 V chargers
for testing purpose.
Blocking Diode: Blocking Diode shall be provided in the positive pole of
the output circuit of each charger to prevent current flow from the DC
battery into the charger.
Annunciation System: Through LEDs following audio-visual indications
shall be provided in the chargers.
a. AC power failure
b. Rectifier/charger fuse blown
c. Over voltage across the battery when boost charging
d. Abnormal (High/Low) voltage
On owners control boardCHARGER TROUBLE indication when above
abnormalities occur
Tests:
Continuous rating
Ripple free output
Voltage regulation
Load limiting characteristic
Insulation resistance
Performance of annunciation system.
b) Battery/ Battery Charger Configurations:

164
Power Division
Figure (a) and (b) gives the main electrical features associated with
battery/battery charger combinations. Charger units are used to supply
either just a battery, provide an autonomous DC supply, or a
battery/inverter combination to provide an autonomous AC supply. The
level of autonomy usually defined in terms of the number of hours or
minutes the equipment will enable the load to function to correctly after
loss of input mains AC supply. The capacity of the charger must also be
such that after a severe discharge it has the capacity to supply the full
DC system load current simultaneously. The technique used for battery
charging is called float charging and involves the battery being
permanently connected to the load in parallel with a charger.
a) Single 100% Battery and 100% Charger:
D.C.DISTRIBUTION
BOARD
MAINS
SUPPLY
BATTERY
CHARGER
BATTERY
b) Semi-Duplicate 2x50% Batteries and 2x100% Chargers:
100%
CHARGER-A
100%
CHARGER-A
50% BATTERY-A
ALARMS
50% BATTERY-A
ALARMS
LV SUPPLY -2
PROTECTION OR
CONTROL
LV SUPPLY -1
PROTECTION OR
CONTROL
230V/132V/33V OR THE ALARM

SUPPLY LMS
230V/132V/33V OR THE ALARM

SUPPLY LMS
114V PROTECTION LMS
114V PROTECTION
LMS
Battery Sizing Calculations:

Capacity and Loads:
The load on the battery is calculated from the power consumption
characteristics of the loads taking into account their nature:
Typical Substation Loads are listed below:
Trip Coils: Load requirements approximately 150 W for less than 1
second. Note that in complex protection schemes (e.g. Busbar
protection) several trip coils may be simultaneously energized and the
165
Power Division
sum of the individual loads must therefore be used in the battery sizing
calculations.
Controls/Relays: Continuous loads such as indicator
contribute to battery discharge on loss of mains supply.
lamps
will
Closing Coils: Older oil circuit breaker coils may take 10-30 kW
depending upon design for less than 1 second at 110 V. More modern
vacuum or SF6 circuit breaker motor wound spring charged mechanisms
and solenoid closing coils have 300-600 W ratings.
DC Motors: Diesel generator black start pump and cranking, isolator or
switchgear drives, air blast circuit breaker air compressor motor drives.
Choice of Voltage: The choice of voltage based on the voltage drops in
the leads at maximum specified load current for cross-section. It also
depends on the rated voltages of various auxiliaries and other sources.
The voltage drops in the leads is calculated from following:
V = 2xRxI
Here V = Voltage drop in
volts, DC
I = Line current in amps, DC
R = Resistance of lead in ohms in one way
V= 2XRxI/kVa
k=conductivity (copper-56%, aluminium-35%)
a=cross-sectional area of lead, mm 2
Also
For medium and small installations, D.C. voltage of 110V is generally

preferred while for large installations, 220V DC is preferred.
Ampere Hour Capacity:
The capacity of battery system is specified in terms of ampere hours. It is
a product of discharge current and the time of discharge. Ampere-hour
capacity is dependant on the magnitude of the discharge current.
Typical Ratings of Battery System:
Hours
10
Current A
7
0
4
0
33
22
13
Ampere-hour
Capacity
7
0
8
0
10
0
11
0
13
0
Maximum discharge current =
Continuousload(W) Shorttimeload(W)
RatedVoltage(V)
The battery capacity and no. of cells shall be arrived at based on the
following duty cycle
Syste
m
Durati
Load
Type of Loads
volta
on
ge
166
Power Division

220V
48V
Continuous load
3 hours
Emergency load
1 hour
Momentary load
1 minute
Continuous load
3 hours
Momentary load
15
minutes
Relays, IEDs, Station HMIs,

spring charging, Isolator
interlocking load,
Miscellaneous permanently
connected loads.
Substation emergency
lighting loads.
Breaker closing, Tripping
loads(taking simultaneous
occurrence as per system).
Continuous load associated
with PLC(when speech is not
working.
Loads associated with PLC
(when speech is working.
Battery Room Ventilation:

The area or enclosure where the battery system is located should have
an adequate level of air changes to prevent buildup of hydrogen gas to
an explosive level. The minimum explosive level is 4% by volume. A
design value of 2% should typically be used. The amount of hydrogen
evolution during operation varies based upon the battery technology in
use and the operating conditions.
D.C Distribution System:
Schemes generally adopted:
i
One battery one charger scheme
ii One battery two charger scheme

iii One battery two charger scheme
One main DC distribution board has to be provided for each battery bank
from which
power is distributed. Proper monitoring system of DC
distribution supply must be defined so that remedial action is taken when
the DC supply fails. In addition to the alarms on the battery/battery
charger combination itself alarms may be derived from failure within the
DC distribution. One main DC distribution board has to be provided for
each battery bank from which power is distributed to the various loads
through switch fuse feeders.
The DC supply is duplicated to each control and relay panel by
sectionalizing the DC distribution and having separate feeders to each
panel. Each relay and control panel DC circuit associated with each
substation circuit is also monitored for loss of DC supply. Since DC failure
could in itself prevent alarms from operating small AC/DC converters
may be specified to drive the annunciation modules.
Complete segregation is maintained between the two main sources
and no mixing is allowed. For this purpose only single core cables are
provided for all inter connections between the batteries, chargers and
main distribution boards. The busbars and connections in the distribution
board would be fully insulated with PVC sleeving or epoxy painting, so as
to minimize the risk of flashover.
Battery Earth Fault Relays:
167
Power Division
The 220V DC system will operate as ungrounded systems. Suitable relays

are provided in the main DC distribution board for detecting single earth
fault. 220V DC system is ungrounded and provides 110V each on positive
to earth and negative to earth.48V DC system is positive grounded .As
DC is vital part in any substation, any second earth fault on 220V system
may affect the system and earth fault need be identified and eliminated.
To give alarm on earth fault relays are provided in the DC system.
AC AUXILURY STATION SUPPLY
AC DISTRIBUTION BOARD
100A F1
100A F1
220V FLOAT CUM BOOST
CHARGER
220V FLOAT CUM BOOST

CHARGER
DC DISTRIBUTION BOARD
DC
100A
(0-300)V (P.M)
10A 10A
F2
220KV
C&R
PANEL
F2
10A
F2
10A
15A
15A
15A
F2
F2
F2
F2
LIGHTING AC
DISTURBANCE BOARD
RECORDER
SPARE
BUSBAR PROTECTION
AND ANNUNCIATION
PANEL
33KV
C&R
PANEL
100A
DC
100A
(0-300)V (P.M)
F2 (BC)
15A
15A
F2
F2
15A 10A
F2
F2
10A
F2
LIGHTING
SPARE
DISTURBANCE
RECORDER
AC
BOARD
10A
F2
10A
F2
33KV 220KV
C&R C&R
PANEL PANEL
BUSBAR PROTECTION
AND ANNUNCIATION
PANEL
Typical Enquiry Data of DC switchboard

1.
Maximum physical dimensions width x depth x height (mm)
2.
Enclosure IP rating
3.
Single line diagram drawing number
4.
Unequipped spare ways
5.
Equipped spare ways
6.
Busbar maximum current rating (A)
7.
Switchgear type
8.
Manufacturer
9.
Manufacturers drawings
10. Metering, alarms and protection Boost charge

11. contactors Anti- paralleling diodes
Notes:
a) Recommend P2 category for repeated short circuit capability
b) Metal-clad, metal enclosed, etc
c) To be completed by the manufacturer
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Power Division
d) To be clearly indicated upon enquiry drawing or detailed circuit by

circuit here. Quiescent and operated power consumption should be
noted.
e) Maximum current rating, coil rating and method of interlocking if
applicable.
Battery Specification:
Sl.N
o.
1
2
3
4
5
6
7
8
9
10
11
12
13
14.
15
16
17
18
19
20
21
22
Technical Particulars
Details
Type of battery and Standard

Electrolyte
Nominal System voltage
Float voltage per cell
Normal system float voltage
required
Normal float charging current
required
Minimum recommended battery
voltage
Recommended boost charging
voltage per cell
Recommended boost charging
current
Dimensions of cell width x depth
x height
Overall Dimensions of battery
bank
width x depth x
height
Overall weight of battery bank
Material of battery cases
Battery capacity i.e.; discharge
rate Amp. hours
Duty cycle requirements
Battery voltage at the end of
duty cycle
Normal standing load
Max. D.C. current capability(short time)
Battery mounting
Connections
Volume of hydrogen produced
during boost charging
Manufacture, type, reference and
manufacturers drawings
Battery Charger Specification:

Sl.N
o.
Details
Particulars
169
Power Division
1.
Max. physical dimensions

-width x depth x height
2.
Charger to suit (type of battery)
3.
1. A.C. input supply for specified

out put -kVA
2. No. of phases single or 3phase
3. Voltage tolerance +/4. Frequency
5. Frequency tolerance +/-
4.
D.C. output
1. Float voltage
2. Boost voltage
3. Float current
4. Boost current
5. Ripple
5.
Psophometric output noise level

for loads between 0% and 100%
as per regulations ( mV @ - Hz)
6.
Noise level limit

( mV rms hum @ - Hz)
7.
Current limitation range
+/-
8.
Voltage limitation range
9.
Time to recharge battery to 90%

capacity from fully discharged
state
10
Charger efficiency
11.
Overload protection
12.
Controls, indications and alarms
13.
Applicable standards
14.
Manufacturer and reference
+/-
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Power Division
AC & DC DISTRIBUTION BOARDS

Distribution Boards:
Construction:
1. All boards shall be of metal enclosed, indoor floor mounted,
compartmenta-lized construction and free standing type.
2. All board frames, shall be fabricated using suitable mild steel
structural sections or pressed and shaped cold-rolled sheet steel of
thickness not less than 2.0 mm. Frames shall be enclosed in coldrolled sheet steel of thickness not less than 1.6 mm. Doors and
covers shall also be of cold rolled sheet steel of thickness not less
than 1.6 mm. Stiffeners shall be provided wherever necessary.
3. All panel edges and cover/door edges shall be reinforced against
distortion by rolling, bending or by the addition of welded
reinforcement members.
4. The complete structures shall be rigid, self-supporting, free from
flaws, twists and bends.
5. All cut-outs shall be true in shape and devoid of sharp edges.
6. All boards shall be of dust and vermin proof construction and shall
be provided with a degree of protection of IP: 52 as per IS 2147.
However, the busbar chambers having a degree of protection of IP:
42, in accordance with IS 2147, arc also acceptable where
171
Power Division
continuous busbar rating exceeds 1000 Amp. Provision shall be

made in all compartments for providing IP: 52 degree of protection,
when Circuit breaker or module trolley, has been removed. All cutouts shall be provided with neoprene/ Synthetic rubber gaskets.
7. Louvers backed with metal screen shall be provided on the busbar
chambers where continuous busbar rating exceeds 1000 Amps.
8. All boards shall be of uniform height not exceeding 2450 mm.
9. Boards shall be easily extendible on both sides, by the addition of
the vertical sections after removing the end covers.
10.
The base frames shall be made of structural steel sections,
along with all necessary mounting hardware required for welding the
base frames to the insert plates, shall be supplied along with the
base frames.
11.
All boards shall be divided into distinct vertical sections, each
comprising of:
(i) A completely enclosed busbar compartment for running
horizontal and vertical busbars. Busbar chamber shall be
completely enclosed with metallic portions. Bolted covers shall
be provided for access to horizontal and vertical busbars and all
joints for repair and maintenance, which shall be feasible
without disturbing feeder compartment.
(ii) Completely enclosed switchgear compartment(s) one of each
circuit for housing circuit breaker or MCCB or motor starter.
(iii) A compartment or alley for power and control cables. Cable alley
door shall preferably be hinged. Cable alley shall have no
exposed live parts, and shall have no communication with busbar
chamber. It shall be of atleast 350mm width.
(iv) A compartment for relays and other control devices associated
with a circuit breaker.
12. Sheet steel barriers shall be provided between two adjacent
vertical panels running to the full height of the switchboard, except
for the horizontal busbar compartment.
Each shipping section
shall have full metal sheets at both ends for transport and storage.
All equipments associated with a single circuit except MCB circuits
shall be housed in a separate compartment of the vertical section.
The Compartment shall be sheet steel enclosed on all sides with
the withdrawal units in position or removed. The front of the
compartment shall be provided with the hinged single leaf door,
with locking facilities.
13. In case of circuits controlled by MCBs, group of MCB feeders can be
LOCATED in common compartment. In such case number of MCB
feeders to be used in a common compartment shall not exceed 4
(four) and front of MCB compartment, shall have a viewing port of
172
Power Division
toughened glass sheet for viewing and sheet steel door of module
shall be lockable with knob/panel key.
14. After isolation of power and control circuit connections it shall be
possible to safely carryout maintenance in a compartment with the
busbar and adjacent circuit live. Necessary shrouding arrangement
shall be provided for this purpose over the cable terminations
located in cable alley.
15. The minimum clearance, in air between phases and between phase
and earth for the entire run of horizontal and vertical busbars, shall
be 25 mm. For all other components, the clearance between "two
live parts", " A live part and an earthed part" and isolating distance
shall be atleast ten (10) mm throughout. Wherever it is not
possible to maintain these clearances, insulation shall be provided
by sleeving or barriers. However, for horizontal run of busbar
minimum clearance of 25 mm should be maintained even if they
are sleeved.
16. The temperature rise of horizontal & vertical busbars when
carrying rated current along its full run shall in no case exceed
55C, with silver plated joints and 40C with all other types of
joints over an outside ambient temperature of 50C.
17. All identical circuit breakers and module chassis of same size shall
be fully interchangeable without having to carryout modifications.
All Circuit breaker boards shall be of single front type, with fully
draw out circuit breakers, which can be drawn out without having
to unscrew any connections. The circuit breakers shall be mounted
on rollers and guides for smooth movement between SERVICE,
TEST and ISOLATED positions and for withdrawal from the
switchboard. Testing of the breaker shall be possible in the TEST
position. Wherever two breaker compartments are provided in the
same vertical section, insulating barriers and shrouds shall be
provided in the rear cable compartment to avoid accidental touch
with the live parts of one circuit when working on the other circuit.
18. All disconnecting contacts for power circuits shall he of robust
design and fully self aligning. Fixed and moving contacts of the
power draw out contact system shall be silver plated. Both fixed
and moving contacts shall be replaceable.
19. All AC & DC boards shall be of single front type.
All modules shall be fixed type except air circuit breaker module,
which shall be drawout type.
The connections from busbars to the main switch shall be fully
insulated/ shrouded, and securely bolted. The partition between
the feeder compartment and cable alley may be non-metallic and
shall be of such construction as to allow cable cores with lugs to be
173
Power Division
easily inserted in the feeder compartment for termination. The

tentative power and control cable entries shall be from bottom.
Adopter panels and dummy panels required to meet the various
busbar arrangements and layouts required shall be included in the
scope of work.
20. All sheet work shall be pre-treated, in tanks, in accordance with IS:
6005. Degreasing shall be done by alkaline cleaning. Rust and
scale shall be removed by pickling with acid. After pickling the
pans shall be washed in running water. Then these shall be rinsed
in slightly alkaline hot water and dried. The phosphate coating
shall be of Class - C as specified in IS: 6005. The phosphated
surfaces shall be rinsed and passivated prior to application of
stoved lead oxide primer coating after primer application, two
coats of finishing synthetic enamel paint on panels shall be
applied. Electrostatic painting shall also be acceptable.
Finishing paint on panels shall be shade 692 (Smoke grey) of IS: 5
unless required otherwise by the PURCHASER. The inside shall be
properly stoved. The paint thickness shall be coated by peelable
compound by spraying method to protect the finished surfaces
from scratches grease din and oily spots during testing,
transportation, handling and erection.
BUS BARS AND INSULATORS:
All AC Distribution Boards shall be provided with three phase buses

and neutral bus bars to carry the specified rated current. All
busbars and jumper connections shall be of high conductivity
aluminium/ copper of adequate size the bus bar size calculation
shall be submitted for approval. The Cross-Section of the busbars
shall be uniform through out the length of Switchgear and shall be
adequately supported and braced to withstand the stresses due to
the specified short circuit currents. All busbars joints shall be
provided with high tensile steel bolts. Belleville/spring washers and
nuts, so as to ensure good contacts at the joints. Non-silver plated
Busbars joints shall be thoroughly cleaned at the joint locations
and suitable contact grease shall be applied just before making a
joint. All busbars shall be colour coded as per IS: 375.
All busbars shall be adequately supported by non-hygroscopic,

non-combustible, track resistant & high strength type Polyester
fibre glass moulded insulators. Separate supports shall be provided
for each phase and neutral busbar.
If a common support is
provided anti-tracking barriers shall be provided between the
supports.
174
Power Division
EARTH BUS
:
1.
A galvanised steel earthing shall be provided at the bottom of each

panel and shall extend throughout the length of each switchboard. It
shall be welded/bolted to the frame work of each panel and breaker
earthing contact bar. Vertical bus shall be provided in each vertical
section which shall in turn be bolted/welded to main horizontal
ground bus.
2.
The earth bus shall have sufficient cross-section to carry the

momentary- short circuit and short time fault currents to earth
without exceeding the allowable temperature rise.
3.
Suitable arrangements shall be provided at each end of the

horizontal earth bus for connecting to the station earthing system.
The horizontal earth bus shall project out the switch board ends and
shall have predrilled holes for this connection.
4.
All non-current metal work of the Switchboard shall be effectively

bonded to the earth bus. Electrical conductivity of the whole
switchgear enclosures, frames work and the truck shall be
maintained even after painting.
5.
The truck and breaker frame shall get earthed while the truck is
being inserted in the panel and positive earthing of the truck and
breaker frame shall be maintained in all positions.
6.
Each module frame shall get engaged to the vertical earth bus.
Before the dis-connecting contacts on these module are engaged to
the vertical busbar. All metallic cases of relays, instruments and
other panel mounted equipments shall be connected to earth by
independent stranded copper wires of size not less than 2.5 mm.
Insulation colour code of earthing wires shall be green. Earthing
wires shall be connected to terminals with suitable clamp connectors
and soldering is not acceptable. Looping of earth Connection which
would result in loss of earth connection to the devices when a device
is removed is not acceptable. However, looping of earth connections
between equipment to provide alternative paths or earth bus is
acceptable.
7.
VT and CT secondary neutral point earthing shall be at one place

only, on the terminal block. Such earthing shall be made through
links so that earthing of one secondary circuit shall be removed
without disturbing the earthing of other circuit.
8.
All hinged doors shall be earthed through flexible earthing braid.

Caution nameplate "Caution-Live Terminals shall be provided at all
points where the terminals are like to remain live and isolation is
possible only at remote end.
Circuit Breakers:
1.
Circuit breakers shall be of three-pole air break horizontal drawout

type and shall have inherent fault making and breaking capacities as
175
Power Division
specified in "Technical Parameters".

2.
Circuit breakers shall be mounted along with it operating mechanism

on a wheeled carriage. Suitable guides shall be provided to minimize
misalignment of the breaker.
3.
There shall be 'Service', Test and Fully withdrawn positions for the
breakers. In 'Test' position the circuit breaker shall be capable of
being tested for operation without energizing the power circuits i.e.
the power contacts shall be disconnected while the Control circuits
shall remain undisturbed. Locking facilities shall be provided so as
lo prevent movement of the circuit breaker from the
SERVICE,
TEST OR FULLY WITHDRAWN position. It shall be possible to close
the door in TEST position.
4.
All circuit breakers shall be provided with 4 NO and 4 NC potentially

free auxiliary contacts. These contacts shall be in addition to those
required for internal mechanism of the breaker.
Separate limit
switches each having required number of contacts shall be provided
in both 'SERVICE' & TEST position of the breaker. All contacts shall
be rated for making continuously carrying and breaking 10 Amps at
240V AC and 1 Amp (Inductive) at 220V DC.
5.
Suitable mechanical indications shall be provided on all circuit

breakers to show 'OPEN', 'CLOSE, 'SERVICE', TEST and 'SPRING
CHARGED positions.
6.
Main poles of the circuit breakers shall operate simultaneously in

such a way that the maximum difference between the instants of
contacts touching during closing shall not exceed half cycle of rated
frequency.
7.
Movement of a circuit breaker between SERVICE AND TEST positions

shall not be possible unless it is in OPEN position. Attempted with
drawl of a closed circuit breaker shall trip the circuit breaker.
8.
Closing of a circuit breaker shall not be possible unless it is in

SERVICE, TEST POSITION or in FULLY WITHDRAWN POSITION.
9.
Circuit breaker cubicles shall be provided with safety shutters

operated automatically by the movement of the circuit breaker
carriage to cover the stationary isolated contacts when the breaker
is withdrawn.
It shall however, be possible to open the shutters
intentionally, against spring pressure for testing purpose.
10. A breaker of particular rating shall be prevented from insertion in a

cubicle of a different rating.
11. Circuit breakers shall be provided with electrical anti-pumping and
trip free feature, even if mechanical anti-pumping feature is
provided.
12. Mechanical tripping shall be possible by means of front mounted
RED Trip' push-button. In case of electrically operated breakers
176
Power Division
these push buttons shall be shrouded to prevent accidental

operation.
13. Breaker controlled motors shall operate satisfactorily under the
following conditions:
i. Direct on-line starting of Induction Motors rated 110 kW to 220
kW with a locked rotor current of seven times the rated current,
and starting time of up to 30 seconds.
ii. Breaking on-load, full load and locked rotor currents of Induction
Motors for rated 100 kW to 220 kW.
14. Means shall be provided to slowly close the "circuit breaker in
withdrawn position. If required for inspection and setting of
Contacts, in SERVICE position slow closing shall not be possible.
15. Power operated mechanism shall be provided with a universal motor
suitable for operation with 220V DC Control supply with voltage
variation from 90% to 110% rated voltage. Motor insulation shall be
class 'E' or better. The motor shall be such that it requires not more
than 30 seconds for fully charging the closing spring. Once the
closing springs are discharged, after the one closing operation of
circuit breaker, it shall automatically initiate, recharging of the
spring. The mechanism shall be such that as long as power is
available to the motor, a continuous sequence of closing and
opening operations shall be possible. After failure of power supply
at least one open-close-open operation shall be possible.
16. Provision shall be made for emergency manual charging and as soon
as this manual charging handle is coupled, the motor shall
automatically get mechanically decoupled.
17. All circuit breakers shall be provided with closing and trip coils. The
closing coils shall operate correctly at all values of Voltage between
85% to 110% at rated control voltage. The trip coil shall operate
satisfactorily under all values of supply voltage between 70% to
110% of rated control voltage.
18. Provision for mechanical closing of the breaker only in "TEST and
'WITHDRAWN' positions shall be made.
Protection Co-Ordination:
The overload and short circuit tripping of the circuit breakers shall be coordinated
with
the
upstream
and
down
stream
circuit
breakers/fuses/motor starters, to provide satisfactory discrimination.
Moulded Case Circuit Breaker (MCCB) and MCB
MCCB shall in general conform to IS: 13947 Part-2. All MCCB shall
be of P2 duty.
MCCB shall be flush mounted on the AC/DC distribution boards.
MCCBs shall be provided with thermo-magnetic type release for

177
Power Division
over current and short circuit protection. The setting of the thermal
release shall be adjustable between 75% to 100% of the rated
current. The MCCB shall have breaking capacity not less than 20
kA.
MCCBs used for ACDB incomers and Bus coupler shall be equipped
with stored energy mechanism for electrical closing and tripping.
All other MCCBs shall be manually operated. The operating handle
should give a clear trip indication.
Miniature circuit breaker (MCB) shall conform to EC: 898-1987 and

IS: 8828.
Relays:
1. All relays and timers in protective circuits shall be flush mounted on
panel front with connections from the inside.
They shall have
transparent dust light covers removable from the front. All protective
relays shall have a drawout construction for easy replacement from
the front. They shall either have built-in test facilities, or shall be
provided with necessary test blocks and test switches located
immediately below each relay. The auxiliary relays and timers may be
furnished in non-drawout cases. All AC relays shall be suitable for
operation, at 50 Hz with 110 volts VT secondary and 1 amp or 5 amp
CT secondary.
2. All protective relays and timers shall have at least two potentially free
output contacts. Relays shall have contacts as required for protection
schemes.
Contacts of relays and timers shall be silver faced and
shall have a spring action. Adequate number of terminals shall be
available on the relay cases for applicable relaying schemes.
3. All protective relays auxiliary relays and timers shall be provided with
hand reset operation indicators (Flags) for analyzing the cause of
operation.
4. All relays shall withstand a test voltage of 2 kV (rms) for one minute.
5. Motor starters shall be provided with three elements, ambient
temperature compensated, lime lagged, hand reset type overload
relays with adjustable settings. The setting ranges shall be properly
selected to suit the motor ratings. These relays shall have a separate
black coloured hand reset push button mounted on compartment door
and shall have at least one changeover contact.
6. All fuse-protected contactor-controlled motors shall have single
phasing protection, either as a distinct feature in the overload relays
(by differential movement of bi-metallic strips), or as a separate
device. The single phasing protection shall operate even with 80% of
the set current flowing in two of the phases.
Contactors:
Motor starter contactors shall be of air break, electromagnetic type

178
Power Division
rated for un-interrupted duty as per IS: 13947 (Part 4).
Contactors shall be double break, non-gravity type and their main

contacts shall be silver faced.
Direct on line starter contactors shall be of utilization category

AC2. These contactors shall be as per IS: 13947 (Part 4).
Each contactor shall be provided with two (2) normally open (NO)
and two (2) normally close (NC) auxiliary contacts.
Operating coils of contactors shall b& of 240V AC unless otherwise

specified elsewhere.
The Contactors shall operate satisfactorily between 85% to 110%

of the rated voltage.
The Contactor shall drop out at 70% of the rated voltage.
Instrument Transformers:
All current and voltage transformers shall be completely
encapsulated cast resin insulated type suitable for continuous
operation at the temperature prevailing inside the switchgear
enclosure, when the switchboard is operating at its rated condition
and the outside ambient temperature is 50C.
All instrument transformers shall be able to withstand the thermal
and mechanical stresses resulting from the maximum short circuit
and momentary current rulings of the associated switchgear.
All instrument transformers shall have clear indelible polarity
markings. All seconding terminals shall be wired to a separate
terminal on an accessible terminal bloc*k where star point
formation and earthing shall be done.
Current transformers may be multi or single core type. All voltage
transformers shall be single phase type. The Bus VTs shall be
housed in a separate compartment.
All VTs shall have readily accessible HRC current limiting fuses on
both primary and secondary sides.
Indicating Instruments:
All indicating and integrating meters shall be flush mounted on
panel front.
The instruments shall be of at least 96 mm square
0
size with 90 scales, and shall have an accuracy class of 2.5 or
better. The covers and cases of instruments and meters shall
provide a dust and vermin proof construction.
All instruments shall be compensated for temperature errors and
factory calibrated to directly read the primary quantities. Means
shall be provided for zero adjustment without removing or
dismantling the instruments.
All instruments shall have white dials with black numerals and
179
Power Division
lettering. Black knife edge pointer with parallax free dials will be
preferred.
Ammeters provided on Motor feeders shall have a compressed
scale at the upper current region to cover the starting current.
Watt-hour meters shall be of 3 phase three element type.
Control & Selector Switches:
1. Control & Selector switches shall be of rotary type with escutcheon
plates clearly marked to show the function and positions. The
switches shall be of sturdy construction suitable for mounting on
panel front.
Switches with shrouding of live parts and sealing of
contacts against dust ingress shall be preferred.
2. Circuit breaker selector switches for breaker Controlled motor shall
have three slay put positions marked 'Switchgear', Normal and
Trial respectively.
They shall have two contacts of each of the
three positions and shall have black shade handles.
3. Ammeter and voltmeter selector switches shall have four stay put
position with adequate number of contacts for three phase 4 wire
system. These shall have oval handles Ammeter selector switches
shall have make before break type contacts to prevent open
circuiting of CT secondaries.
4. Contacts of the switches shall be spring assisted and shall be of
suitable material to give a long trouble free service.
5. The contact ratings shall be at least the following:
(i)
Make and carry continuously
10 Amp.
(ii)
Breaking current at 220V DC
I Amp (Inductive)
(iii)
Breaking current at 240V AC
5 Amp (at 0.3 of lagging)
Air Break Switches:
Air breaker switch shall be of the heavy duly, single throw group
operated, load break, and fault make type complying with IS: 4064.
The Bidder shall ensure that all switches are adequately rated so
as to be fully protected by the associated fuses during all abnormal
operating conditions such as overload, locked motor, short circuit
etc.
Switch operating handles shall be provided with padlocking

facilities to lock them in OFF position.
Interlocks shall be provided such that it is possible to open the

cubicle door only when the switch is in "OFF position and to close
the switch only when the door is closed. However suitable means
shall be provided to intentionally defeat the interlocks explained
above.
Switches and fuses for AC/DC control supply and heater supply
wherever required shall be mounted inside and cubicles.
180
Power Division
Push Buttons:
Push-buttons shall be of spring return, push to actuate type. Their

contacts shall be rated to make, continuously carry and break 10A
at 240V and 0.5A (inductive) at 220V DC.
All push-buttons shall have one normally open and one normally
closed contact, unless specified otherwise. The contact faces shall
be of silver or silver alloy.
All push-buttons shall be provided with-integral escutcheon plates

marked with its function.
The colour of the button shall be as follows:

(i)
GREEN
(ii)
RED
(iii) BLACK
: For motor START, Breaker CLOSE

: For motor TRIP, Breaker OPEN
:
For overload reset.
All push-buttons on panels shall be located in such a way that Red-pushbuttons shall always be to the left of green push-buttons.
Indicating Lamps:
Indicating lamps shall be of the panel mounting cluster LED type.
The lamps shall have escutcheon plates marked with its function,
wherever necessary.
Lamps shall have translucent lamp-covers of the following colours,
as warranted by the application:
Wired with 2.5 square mm copper wires.
insulation shall be same as above.
Voltage grade and
Extra-flexible wires shall be used for wiring to device mounted on

moving parts such as hinged doors.
All wiring shall be properly supported, neatly arranged, readily
accessible and securely connected to equipment terminals and
terminals blocks.
Power Cables Termination:
Cable termination compartment and arrangement for power cables
shall be suitable for stranded aluminium conductor, armoured
XLPE/PVC insulated and sheathed, single core/three core, 1100 V
grade cables.
All necessary cable terminating accessories such as Gland plates,
supporting clamps and brackets, power cable lugs, hardware etc.
shall be provided by the successful bidder, to suit the final cable
sizes which would be advised later.
The gland plate shall be of removable type and shall cover the
entire cable alley. Bidder shall also ensure that sufficient space is
181
Power Division
provided for all cable glands. Gland plates shall be factory-drilled

according to the cable gland sizes and number which shall be
informed to the contractor later. For all single core cables, gland
plates shall be of non-magnetic material.
Type Tests:
Type tests reports on Panels (Switchgear and control gear assemblies) as
per IS 8623 Part- I shall be submitted for the following tests in line before
the fabrication of switchgear is started:
i.
ii.
iii.
iv.
v.
vi.
vii.
Verification of temperature rise limits

Verification
Verification
Verification
Verification
Verification
Verification
of
of
of
of
of
of
the dielectric properties

short circuit strength
the continuity of the protective circuit
clearances and creepage distances
mechanical operation
degree of protection
Automatic Control of Outdoor Lighting:

EL type module of 415 V main lighting distribution board and emergency
lighting distribution board and shall be controlled by timer and contactor
module to facilitate its operation automatically.
Automatic Supply Changeover:
Automatic changeover between Incomer I, Incomer II, and DG set is to be
carried out during the failure of supply in one/or both the incomers. After
the restoration of the supply, system shall be restored to normal
condition automatically. The requirement of changeover under various
conditions are as below:
(i)
Under normal conditions i.e. when supply is available in both the

incomers, incomers I & II of 415 V Main switchboard, ACDB shall be
in closed condition and Bus couplers and DG set breaker shall be in
open condition.
(ii) In case of failure of either of the sources, the incomer of that

source shall trip and Bus coupler shall get closed. On restoration of
supply, normal conditions described above are to be established
automatically.
(iii) In case of failure of supply in both the sources, both incomers,
incomers of ACDBs and ACDB Bus coupler shall trip and DG set
breaker switched on. On restoration of one or both sources, DG set
breaker shall trip, DG set stopped and conditions described in
paragraph (i) /(ii) shall be restored.
To avoid unnecessary operation of switchgear for momentary
disturbances all changeovers from one state to another shall be initiated
after a time delay, after the conditions warranting such change has been
detected.
182
Power Division
Modules & Components in the Distribution Board:

Each AC & DC Distribution Board shall comprise of a number of different
types of modules as described hereunder.
Module Type: AE (Electrically controlled circuit breaker for

incoming and Bus Coupler Circuit).
(i)
(ii)
One (1) Triple pole air circuit breaker complete with all
accessories and power operated mechanism
as specified.
Two (2)
Neutral link.
(iii) Three (3) Current Transformer for metering.

(iv) One (1)
(v)
Ammeter with selector switch.
Three (3) Current Transformer for relaying.
(vi) One (1)
Triple pole instantaneous over-current relay

having the setting range of 200-800% or 5002000% or CT secondary and adjustable
definite minimum time.
(vii) One(l)
Instantaneous earth fault relay having an

adjustable setting range of
10-40% or 2080% of CT secondary current and adjustable
definite minimum time. The earth fault relay
shall be provided with a stabilizing resistor.
Modular Type M1 (Circuit Breaker Controlled Motor Feeder):

Triple pole Air Circuit Breaker complete with accessories, and power
operated mechanism as specified.
(i)
(ii)
One (1) Triple pole air circuit breaker complete with all
as specified.
One (1)
Three position 6 pole selector switch SWITCH

GEAR/NORMAL/TRIAL.
(iii) Three (3) Current Transformer for metering.

(iv) One (1)
(v)
Ammeter with Ammeter selector switch.
Three (3) Current Transformer for relaying.
(vi) One (1)
Triple pole instantaneous over-current relay for

providing positive sequence current protection
in all the three phases. The relay setting range
shall be continuously adjustable between 200800% or 400-1600% of CT secondary rated
current as required.
(vii) One (1)
Double pole inverse definite minimum time

over current relays connected in R & B phases
183
Power Division
for over current protection of motor rated 110

kW - 200 kW. The relay shall have an
adjustable setting range of 50% - 200% of CT
Secondary current and time setting range of
0-30 second. The relay shall be CDGM-22 of
EE or equivalent.
(viii) One(l)
Single pole adjustable definite lime delay

relay for motor overload alarm connected in Yphase only. The relay shall have reselling ratio
of no. 1 less than 90%. The relay shall have
continuously adjustable lime delay range of
2.5 lo 25 sec.
(ix) One(l)
Instantaneous earth fault relay having an

adjustable setting range of 10-40% or 20-80%
of CT secondary current. The earth fault relay
shall be provided with a stabilizing resistor.
Module Type E:
(i)
One (1) Four pole MCCB
Module G-1 (VT Module with under Voltage Ready):
(i)
415
Three (3)
110
volts
single
phase
voltage
transformer star/star connect with stat point

solidly earthed mounted on common draw out
chassis. Accuracy class 0.5 for protection and
metering with 50 VA Burden.
(ii) Six (6)
HRC Fuses mounted on the above chassis.
(iii) One (1)
Four position voltmeter selector switch.
(iv) One (1)
Voltmeter (0-500 V)
(v)
One (1)
Double pole instantaneous under voltage

relays with continuous variable setting range
of 40-80% of 110 volts.
(vi) One (1)
Time delay pick up relay having a time setting

range of 0.5 to 3 sees with 3 NO. Self reset
contacts, suitable for 220V DC.
(vii) One (1)
Auxiliary relay 220 V DC with 2 No. self reset

contacts.
184
Power Division
(viii) Three (3) Indicating lamps with series resistor and

colour lenses (Red, Blue & Yellow).
Module Type G-2:
(i)
One (1) Four pole MCCB
(ii)
One (1) Red indicating lamp to indicate isolating

switch closed position.
Module Type S: (DC Metering and Protection Module):

i)
ii)
(iii)
One (1)
One (1)
Volt meter 300-0-300 V DC for 220 V DC

DB/Voltmeter 0-75V DC for 50 V DCDB.
Three(3) position voltmeter selector switch.
One (1) Instantaneous over voltage relay with 95% of

220 V DC. The resisting ratio of relay of relay
should not be more than 1.25. The relay shall
be provided with a series resister and a push
button across if for resetting (pickup) the relay
at about 105% of the drop out voltage.
iv)
One (1)
v)
One (1)
Instantaneous over voltage relay with setting

range of 110% of 220V DC. The resetting ratio
of relay should not be less than 0.8. The relay
shall have a push button in series of resetting
the relay at about 95% of the operating
voltage.
Earth leakage relay only for 220V DC system

having adjustable pick up range between 3 to
7 milliamps the relay shall be suitable for
220V DC/240V AC Auxiliary supply.
Module Type X: (DC Incomer from Battery Charger)
i)
One (1)
Double pole 250 V DC MCCB for incomer from

battery.
ii)
One (1)
DC ammeter with shunt and range of 90-0400 Amps, For 220 V DC DB and 90-0-200
Amp for 50V DC DB.
iii)
One (1)
Double pole 250V DC MCCB/MCB
iv)
Two (2)
Double pole single throw 250 V DC air break

switch connecting battery & charger sections
to DC DB.
Module Type DG-1 (Electrically Controlled Circuit Break for

Incomer from DG Set):
185
Power Division
i)
One (1)
Triple pole circuit breaker complete with all

as specified.
ii) One (1)
Frequency meter.
iii) One (1)
Voltmeter with selector switch.
iv) One (1)
Remote/Local Selector switch.
v) Three (3)
Current transformer for metering.
vi) Six (6)
Current transformers for differential protection

(out of this 2 Nos. will be supplied loose for
mounting in DG set panel.
vii) Three (3)
Current transformer for relaying.
viii) One (1)
Ammeter selector switch.
ix) One (1)
Ammeter
x) One (1)
Watt meter of range 0-300 kW.
xi) One (1)
Three pole voltage controlled definite time

delay relay having current setting range of 50200% of CT secondary current and adjustable
time delay 0.3 to 3 sec.
xii) One (1)
Watt hour meter with six (6) digits and

minimum count of one (1) kwh.
xiii) One (1)
Single pole definite time over current relay

having a continuous setting range of 50-200%
of CT secondary current and a time delay of
2.5-25 sec. connected in CT of Y phase for
overload alarm. The relay shall have a setting
ratio of not less than 90%.
xiv) One (1)
Three pole differential protection relay having

an operating current setting range of 10-40%
of generator full load current. The relay shall
be of high impedance type, with necessary
stabilizing resistors.
xv) Two (2)
Push buttons for remote starting & stopping of

DG set (Red, Green).
Module Type H1:

i)
One (1)
Double pole DC switches with pad locking

facility in off position.
Module Type EL:

i)
One (1)
Four pole MCCB.
ii)
One (1)
Contractor.
iii) Electronic Timer suitable for continuous operation, push

button and selector switch be as per scheme requirement.
186
Power Division
Technical Parameters:
Power Supply:
AC System
3 Phase, 4 wire, solidly earthed
b) Voltage
415 volts, 10%
c) Frequency
50 Hz 5%
d) Combined variation
10% absolute sum in voltage & frequency.
e) Fault level
20 kA (rms)
DC System
2 Wire, unearthed
a) System voltage
220 V 10%
b) Fault level
4 kA
c) System voltage
50 V 10%
d) Fault level
--
Cubicle Date:
Busbar Rating:
a) Continuous
for vertical panels
As required
b) Short time (1 sec.

kA (rms)
20 kA
c) Momentary (kA)
Peak
45 kA
d) Ambient Temperature
500C
e) One Minute Power Frequency withstand:

I. Power Circuit
2500 volts (rms)
II. Control Circuit
2500 Volts (rms)
Cubicle Colour Finish:

b) Interior
Glossy white.
c) Exterior
Smoke Grey shade No. 692 of IS: 5.
Circuit Breaker:
a) Type
b) No. of pole
c) Voltage & Frequency
Air break
3
415 10%, 50 Hz + 5%
d) Rated Operating Duty
B-3 Min, M-B-3 Min. MB
e) Symmetrical
Interrupting rating
20 kA (rms)
187
Power Division
f) Short circuit making

current
45 kA (peak)
g) Short time withstand

current for 1 sec
duration
20 kA (rms) for 1 sec.
h) Operating Mechanism
Current for 1 sec
Duration
20 kA (rms) for 1 sec.
i) No. of auxiliary contacts
4 No. & 4 NC contacts for purchasers

use on fixed portion of the cubicle.
j) Short circuit breaking current:

I. AC Component
20 kA (RMS)
II. DC Component
As per IS: 13947(Part 2)
Moulded Case Circuit Breaker:

AC System
a) No. of Poles
DC System
b) Voltage & Frequency
415 10%
250 V
c) Rated Operating Duty
P2
P2
d) Symmetrical interrupting
Rating
20 kA (RMS)
4 kA
e) Short circuit making current 45 kA (peak)

f)No. of auxiliary contacts
2 NC
--
2 No. & 2 NC
2 No. &
g) Short circuit breaking current:

I. AC Component
20 kA (RMS)
As per IS
II. DC Component
IS 13947
IS 13947
2.5
--
b) One minute power Frequency

withstand test voltage in kV 2.0
--
Meters:
a) Accuracy class
Current Transformers:
a) Type
Cast resin, Bar primary
b) Voltage class and frequency 650 V, 50 Hz.

c) Class of insulation
E or better
d) Accuracy class
but
metering CT
Class 1, VA adequate for application,
e) Accuracy class
5 P 15, VA adequate for application,
not less than 7.5 VA.
188
Power Division
but
Protection CT
f) Accuracy class
Differential protection
not less than 7.5 VA.

PS, KPV = 300 V
g) Short time current rating (for CTs associated with circuit

breakers):
I.
Current
20 kA (rms)
II. Duration
One second
III. Dynamic Rating
45 kA (peak)
IV. One minute power

frequency withstand
test voltage
2.5 kV (rms)
Voltage Transformer:
b) Type
Cast Resin
c) Rate Voltage
Primary
Secondary
415/3 V
110/3 V
d) Method of connection
Primary
Secondary
Star
e) Rated Voltage factor
1.1 continuous, 1.5 for 3 seconds
Star
f) Class of insulation
E or better
g) One minute power frequency

Withstand voltage
2.5 kV (rms)
h) Accuracy class
0.5, not less than 20 VA.
Relay:
a) One minute power frequency
withstand test
2 kV (rms)
AC Distribution Board in Control Room:
189
Power Division
AC Distribution Board in Outdoor Yard:
Incoming & Outgoing Feeder Cable Sizes:

(for a Typical 400/220 kV Substation)
190
Power Division
Sl.
No.
A.
1.
3.
5.
7.
9.
XLPE Cable
Size
For AC Distributions
For 150 A incoming feeders
from Station Service
Transformers I & II of 630
kVA
3:3 1C 630
sq.mm
46 mm/1C
2 1C 630
sq.mm
46 mm/1C
For 800 A incoming & outgoing

feeders

feeders

feeders
Switchyard lighting panel etc.
13.
14.
B
1.
2.
3.
3:2 1C 630
sq.mm
2 1C 300
sq.mm
3:2 1C 300
sq.mm
11C 500
sq.mm
3 1C 300
sq.mm
11C 500
sq.mm
46 mm/1C
36 mm/1C
36 mm/1C
41 mm/1C
41 mm/1C
25 mm/1C
For 200 A & 150 A & 125 A incoming & outgoing feeders
220 V Battery chargers & PLCC
Battery Chargers
12.
Overall
diameter of
cable;
tolerance 2
mm
Description of Cables
required

feeders
feeders
feeders
[3.5C70 sq.mm
+
3.5C35 sq.mm ]
(33 mm + 27
mm)
3.5C70 sq.mm
33 mm
3.5C35 sq.mm
27 mm
3.5C35 sq.mm
27 mm
2C185 sq.mm
39 mm
2C10 sq.mm
20 mm
2C6 sq.mm
18 mm
For DC Distribution Boards

For 200 A incoming from
Battery Charger I & II for DCDB
feeders
feeders
191
Power Division
CONTROL AND RELAY PANELS

Power System Control Systems:
1. Substation Control System (SCS)
2. Power Plant Control System (PCS)
3. Substation Monitoring System(SMS)
4. Supervisory Control And Data Acquisition System (SCADA)
5. Energy Management System(EMS)
6. Distribution Management System(DMS)
Functions of Protective Relaying:
Protective relaying is to remove from service any element of a power
system in case of any abnormal conditions like short circuits and earth
faults.
Objectives:
i. Reliability:
When a fault occurs the relay shall operate instantly and
correctly.
ii. Selectivity:
The relay must act fast with in its primary zone and shall have
delayed operation in its backup zone.
iii.Sensitivity:
The relaying equipment must be sufficiently sensitive so that it
operates reliably when required under the actual conditions that
produces least operating tendency.
iv. Speed:
It is desirable that the relay operates at the required speed. As
per IEEE 100-1984 a high speed relay is one that operates in less
than 50 seconds. Modern high speed circuit breaker operates in
the range of 17 to 50 milliseconds others operate at less than 83
milliseconds. Thus the totals clearing time (relays plus breaker
ranges from 35 to 135 milliseconds.
v. Simplicity and Economic:
A protective relay system shall be kept simple with minimum
circuitry. The use of solid state and digital technologies in
192
Power Division
protective relaying provide much convenient possibility for

increased sophistication.
Classification of Relays:
Based on
Functions
Based on
Operating
Principles or
Structure:
Based on
Inputs
Based on
Performance
Characteristic
1. Protective
relays
1. Current
1. Current balance
1. Distance
2. Voltage
2. Multi restraint
2. Monitoring
relays
3. Power
3. Re-closing
relays
4. Pressure
3. Product solid
state
2. Directional
over current
5. Frequency
4. Micro processor
4. Definite time
4. Regulating
relays
6. Temperature
5. Electromechani
cal
5. Under voltage
5. Auxiliary
relays
8. Vibration
6. Thermal
7. Ground or
phase
7. Flow
3. Inverse time
6. Over voltage
8. High or low
speed
6. Synchronizing
relays
9. Phase
comparison
10. Direction
comparison
Types of Panels:
a.
Control Panels
b.
Relay Panels
c.
Control and relay Panels
d.
Synchronizing Panels
e.
Communication Panels
f.
Annunciation Panels
g.
Charger Panels
h.
Auxiliary control Panels
i.
M.G Panels
j.
Machine Panels
k.
Duplex HV, LV Panels
l.
Bus zone protection Panels
m. OLTC / RTC Panels

193
Power Division
n.
RTI Panel
Basic Structure of Protection System:

From Protected unit physical variables (abnormal current, voltage,
temperature etc.)
To Transducers (CT, VT, Temperature sensors etc.)
To Protection device
To Auxiliary circuit
DC supply from battery to breaker tripping circuit and Display and
recording devices to the control circuit.
Factors Influencing Protection:
i. System lay out
i. Substation layout
ii. Location of CTs
iii. System earthing
Types and Causes of Failure:
Sl.No
.
Type
Causes
1.
Insulation
Design defects or
errors
Manufacturing
defects
Erection defects
Aging
Contamination
2.
Electrical
Lightning surges
Switching surges
Dynamic over
voltages
3.
Thermal
Over current
Over voltage
Cooler failure
Ambient temperature
4.
Mechanical
Short circuit forces

Earth quake
Foreign object impact
Winds, Snow or ice
Types of Faults:
194
Power Division
Three phase faults
Phase to phase faults
Two phase ground faults
Open circuit faults
Simultaneous faults(multiple faults)
Faults and System Variables Used for Detection:

Sl.N
o.
1.
Fault
Variable Used for Detection
Phase fault
Phase current
Current difference
Phase angle difference
Phase voltage
Power direction
Impedance
2.
Asymmetric faults
(phase to phase and
phase to ground)
Phase current
Current difference
Phase angle difference
Phase voltage
Power direction
Impedance
Negative and zero sequence
components of current and
voltage
Power directions
3.
Ground faults
Zero sequence components of

current and voltage
Power directions
4.
Over load
Phase current
temperature
5.
Asymmetrical
configuration
Asymmetric load
Interrupted conductor
Negative sequence components

of current and voltage
6.
Real power deficit
Frequency (rate of change)
7.
Real power excess
Frequency
Substation Control System (SCS)
195
Power Division
Conventional equipment for control, monitoring and protection in a

substation has traditionally been designed with a combination of discrete
static and electro-mechanical devices. Control of switching devices,
interlocking, alarms, disturbance recording, protection, measuring and
metering are some of the sub-systems and all of these require individual
wiring.
Protective Relays:
Protective relays are essential components of power system. The
protective relay is an electrically operated device designed to sense the
identified circuit parameters and to initiate disconnection of the intended
part of an electrical section in case of an abnormal condition in the
installation and with minimum interruption to overall system, with or
without warning signal.
Types of Relays:
First Generation
: Electromechanical and Electro Magnetic Relays
Second-Generation : Static Relays

Third Generation
: Numerical Relays
Electromechanical Relays:
These relays operate on the principal of a mechanical force generated
due to the current flow in a coil wound on a magnetic core. This force
results in the operation of a contact arrangement which is used for
relaying the operated condition to the desired circuit in order to achieve
the required function. Since the mechanical force is generated due to an
electric current flow the term electromechanical relay. These relays
operate on any one of the fundamentally different operating principles,
viz., electromagnetic attraction and electro magnetic induction. The
operation of relay means it changes the state of its contacts from
normally open condition (NO) to close condition or normally closed
condition (NC)to open condition.
Types of Electromechanical Relays:
1. Thermal
a) O.T.Trip
a) W.T. Trip
b) Lamp trip etc.
2. Float type
a) Buchholtz
a) OSR
b) PVR
196
Power Division
c) Water level controls etc.

3. Pressure switches
4. Mechanical interlocks
5. Pole discrepancy etc.
Types of Electro Magnetic Relays

Auxiliary Relays
1. Annunciation relays
2. Inter trip relays
3. Multi contactor D.C. operated relays
4. Time delay relays
5. Fuse failure relays
6. Trip circuit supervision relays
Types of Static and Numerical Relays:
Based on
Actuation
1.Current
relays
2.Voltage
relays
3.Frequency
relays
4.Power relays
Based on Time
Character
1. Definite time relay
Inclusive of Logic
1. Differential
2. Inverse time relays

2. Unbalance
with DMT (IDMT)
3. Inverse time relays
3. Neutral
with DMT and
displacement
instantaneous element
4. Stepped characteristic 4. Directional
5. Programme switches
etc.
5. Restricted earth
fault
6. Over fluxing
7. Distance scheme
8. Busbar protection
9. Reserve power
relays
10. Loss of
excitation
11. Negative phase
sequence
Device Numbers and their Universal Nomenclature:

Time delay starting or closing relay
Checking or Interlocking relay
3
197
Power Division
Distance relay
21
Check synchronizing relay
25
Under voltage relay
27
Flame detector
28
Isolating contactor
29
Annunciator relay
30
Directional(reverse power) relay
32
Low forward power relay
37
Field failure (loss of excitation)
40
Negative phase sequence relay
46
Machine or transformer thermal relay
49
Instantaneous over current relay
50
A.C.IDMT over current relay
51
Circuit breaker
52
Circuit breaker auxiliary switch Normally open(a contact)
52a
Circuit breaker auxiliary switch Normally closed(b contact)
52b
Power factor relay
55
Field application relay
56
Over voltage relay
59
Voltage or current balance relay
60
Earth fault relay
64
Directional relay
67
Locking relay
68
Alarm relay
74
D.C. Over current relay
76
Phase angle measuring or out of step relay
78
A.C.auto recluse relay
79
Frequency relay
81
Under frequency relay
81U
Over frequency relay
81O
Automatic selective control or transfer relay
83
Carrier or pilot wire receive relay
85
Tripping relay
86
Differential relay
87
Generator differential relay
87G
Overall differential relay
87GT
198
Power Division
UAT differential relay
87U
Restricted earth fault relay(provided on HV side of Generator

Transformer
87N
T
Trip circuit supervision relay
95
Over flux relay
99
Auto reclose lockout relay
186A
Auto reclose lockout relay
186B
Transformer Protection:
Faults within the Transformer Tank:
1.
2.
3.
4.
5.
6.
7.
Phase-to-phase
Phase-to-earth
Inter turn fault on the windings
Inter winding faults
Tap changer faults
Insulator bushing failure
Core overheating due to failure of core insulation
Buchholtz Relay:
The incipient faults in transformer tank below oil level actuate Buchholtz
relay so as to give alarm. The arc due to fault cause decomposition of
transformer oil. The decomposition of the oil starts at about 150 0C. The
product of decomposition contain more than 70% of hydrogen gas, which
being light rises upward and tries to go in to the conservator. The
Buchholtz relay is fitted in the pipe leading to the conservator. The gas
gets collected in the upper portion of the Buchholtz relay thereby the oil
level in the Buchholtz relay drops down. The float, floating in the oil in the
Buchholtz relay tilts down with the lowering oil level. While doing so, the
mercury switch attached to the float is closed thereby closing the alarm
circuit. The transformer is disconnected soon and the gas samples are
tested to find out the nature of fault. Whenever there is heavy fault inside
the transformer, due to serious short circuit a heavy surge is created due
to sudden build-up of pressure in the oil, which is caused by the
decomposition of the oil by the arc. The oil rushes towards the conservator.
While doing so it passes through the Buchholtz relay. The baffles (plates) in
the Buchholtz relay get pressed by the rushing oil. There by they close
another switch, which in turn closes the trip circuit of circuit breaker,
isolating the transformer.
Note:
1. The Buchholtz relay can be used only for transformers with
conservator. The relay is not provided for transformers below 500
kVA for economic considerations.
2. A separate Buchholtz relay is provided with the tap-changer.
199
Power Division
3. The relay is slow; minimum operating time is 0.1 second, average

time
0.2 second.
4. For faults above oil level, the relay does not act.
5. IS: 3638 Application Guide For Gas Operated Relays gives details
about gas analysis.
Faults on the Transformer Connections:

1. Faults between the CT and the associated circuit breaker
2. Failure of cooling system
3. Sustained over load
4. Short circuit s in busbars
5. Line faults
Relays to be provided on Transformers of Different Ratings:
Sl.N
o.
1.
Rating of
Transforme
r
132/33/11
kV
Up to 8
MVA,
2.
132/33/11
kV
above 8
MVA up to
31.5 MVA
3.
Relays on
HV side
Relays on
LV side
Common Relays
3 O/L relays 2 O/L relays Buchholtz,

+1 E/L
relay
+1 E/L
relay
OLTC Buchholtz, OT,WT
3 O/L relays 3 O/L relays Differential

+1 dir. E/L
relay
+1 E/L
relay
Buchholtz,
OLTC Buchholtz ,OT,WT
132/33 kV
3 O/L relays 3 O/L relays Differential, Over Flux,
31.5 MVA
and above
+1 dir. E/L
relay
+1 E/L
relay
Buchholtz,
OLTC Buchholtz,
PRV,OT,WT
4.
220/33 kV
3 O/L relays 3 O/L relays Differential, Over Flux,
31.5 MVA
and above
+1 dir. E/L
relay
+1 dir .E/L
relay
220/132 kV
Buchholtz,
OLTC Buchholtz,
PRV,OT,WT
100 MVA
5.
400/220 kV
315 MVA
3
directional
O/L relays
(with dir.
3
directional
O/L relays
(with dir.
200
Power Division
Differential, Over Flux,

Buchholtz,
OLTC Buchholtz,
Highest)
Highest)
PRV,OT,WT
+1 dir. E/L
relays
+1 dir. E/L
relays
and over
load(alarm)relay
Restricted
earth fault
relay
Restricted
earth fault
relay
Permissible Duration of Over Load:

Over load
%
Duration
minutes
125
150
175
200
300
125
45
15
10
Typical Oil Temperature Settings for Thermal Over-heating

Protection:
Switch on fans : 600C
Alarm
: 950C
Trip
: 1200C
Bus Zone Protection:

The causes for bus zone faults:
Failure of support insulator resulting in earth fault
Flashover across support insulator during over voltages
Heavy pollution on insulators
Failure of connected equipment
Effect of Bus Faults:
Fault level high
System stability gets affected due to bus faults
Supply to major portion of system gets affected
Desirable Features of bus Protection:
High speed.
Stability for external faults.
Discrimination between fault in its protected section and fault

elsewhere.
Freedom from unwanted operation.
No operation due to CT saturation or power swings.

201
Power Division
Separate control of trip circuit of each circuit breaker.
Main and check protection to assure the disconnection only

when desirable.
Interlock over current protection to trip generator unit if buszone protection operates.
Non auto reclosure and no single pole tripping of circuit

breakers for bus fault.
Methods of Bus-zone Protection:

Sl.N
o.
Method
Particulars
Remarks
Used in distribution system
(6-33 kV) with
transformers/ feeder supply
to bus bars
1.
Over-current
relays of
connected
circuits
High set instantaneous

over current relays and
earth fault relays or
definite time relays
2.
Differential
protection
( Used in major
substations)
1. High impedance
1. High impedance
circulating current
connected in series with
differential
relay coil to improve
protection
stability
2. High impedance
2. Voltage drop across
differential
impedance is measured
protection based on
for discrimination
voltage drop
3. Biased coil gives
3. Biased differential
restrain for external
protection
faults
Frame leakage
earth fault
protection for
low voltage
metal clad
switchgear
bus
Static
protection by
High
Impedance
differential
Back-up
protection
The metal frame of

switchgear (lightly
insulated from earth)
earthed only through
CT. Each fault rely
connected to secondary
of the CT
Rapid and reliable. No
problem of CT
saturation
Earth fault protection of

metal clad switchgear
Over-current protection
or distance protection
The zone of primary

protection of feeders is
extended to cover bus zone
4.
5.
Preferred in modern
installations
Control and Relay Panels contain the following circuits

1. AC Circuits
2. DC Circuits
3. CT Circuits
4. PT/CVT Circuits
202
Power Division
Control Panels are used for: Mounting all the control switches,
selector switches, indications, semaphores and instruments required.
Relay Panels are used for:
Mounting all the Protection Relays and instruments required.
The terminal blocks shall be 1100v grade and 10Amps continuous rating,
moulded piece, complete with insulated barriers, stud type brass
terminals, washers nuts, locknuts and identification strips. All terminal
blocks shall have shouldering with transparent unbreakable material.
AC Supply to be extended to:
1. Control Panel
2. Circuit Breaker Marshaling Box
3. Switch Yard Bay Marshalling Box
4. Current Transformer Marshalling Box
5. CVT / PT / EMVT Marshalling Box
6. ISOLATOR Operation (3-Ph)
7. Circuit Breaker Operating Mechanism Drive(3-Ph)
AC Supply needed for the following:
1. Door lamp
2. Panel heater
3. Plug socket
4. Aux supply to annunciation fascia
5. Auxiliary supply to transducer circuit
6. DC fail circuit
DC Supply for:
1. Indication circuits
2. Annunciation circuits
3. Circuit breaker closing coil & trip coil-1 ckt
4. Circuit breaker trip coil-2 ckt
5. To synchronization circuit
6. To main-1(21m1/ 87t) protection
7. To main-2 or bus (21m2/ 67) protection
8. To AC supervision
9. To isolator control
10.
To isolator interlock
Indication Circuits:
203
Power Division
1. CB 52 CLOSE & OPEN

2. CB 52 TC-1 HEALTHY
3. CB 52 TC-2 HEALTHY
4. CB 52 SPRING CHARGED
5. CB 52 CAPACITOR CHARGED
6. CB 52 SEMAPHORE INDICATIOR
7. BUS ISOLATOR 29/89 CLOSE & OPEN
8. BUS ISO 29/89 SEMAPHORE INDICATOR
9. LINE ISOLATOR 29/89L CLOSE & OPEN
10.
LINE ISO 29/89L SEMAPHORE INDICATOR
For 400 kV Stations there shall be two separate Battery systems

available for Protection, Control & Tripping/Closing Operations. To obtain
redundancy and to be able to take Protection out for maintenance, while
equipment is in service, the Relays are electrically and physically
segregated in to two groups. Grouping is done to the extent possible in
such a way that each group can independently carryout Protective
functions with near equal redundancy. Inter connection of these two
groups shall not be generally be attempted.
Distribution of DC supply shall be done bay wise to feed the following:
1. Protection,
2. CB control,
3. Isolator / earth switch control and
4. Annunciation / indication.
204
Power Division
205
Power Division
OIL HANDLING SYSTEM

The oil handling system is required for treatment of insulating oil in
transformers and reactors.
Transformer Oil:
Transformer oil is petroleum based oil is obtained by refining petroleum
by a number of processes its purpose is to provide insulation and cooling.
Only petroleum based transformer oil is used widely, though several
synthetic insulating fluids based on synthetic hydro carbons, esters and
silicones are developed.
The transformer oil is obtained by the
distillation of the petroleum crude fractions, boiling between 300 0C to
4000C. This is called Transformer Oil Base Stock (TOBS).All petroleum
crude consists mainly of hydro carbons viz., Paraffin, Naphthalene and
Aromatics. As per IS 335, resistivity and tan delta are specified at 90 0C.
Their values are 35 1012 ohm cm and 0.002. The acceptance limits of
the above for the oil received in drums at site is specified as 1 1012
ohm-cm and 0.05.
Broadly the Transformer Oil is:
(1)Paraffin based
(2)Naphthalene based
(3)Aromatic based
(4)Non Hydro-carbon based
(a) Sulphur compounds (Natural inhibitor)
(b)Nitrogen compound
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Power Division
Treatment of Transformer Oil:

General Diagram for Treatment of Oil and Conditioning of
Transformer Oil:
Steps Involved in Treatment of Transformer Oil:

1. Long storage of the transformer oil is not recommended.
2. Store oil drums properly.
3. Oil shall be filled in the Transformer tank as soon as nitrogen is
expelled.
4. Care is to be taken so as not to allow any foreign object falling into
the transformer.
5. Transformer oil must be pumped from the drums to the storage tank
through purifier.
6. Leave about 20mm oil at the bottom of each drum. It may be
impure.
7. Pumping in oil must be through the drain valve. Leave one opening
at the top open to release entry air.
8. Before commencing oil filling and purification, clean the top of oil
drums, flush hoses, oil tank, and the filter also.
9. Oil pockets for OTI & WTI must be filled with oil before fitting the
sensing bulbs.
10. For transformers rated below 66kv vacuuming is to be done at
below 380mmHg.
11. For transformers above 66kv vacuuming is to be done at 760mm of
Hg.
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Power Division
12. Equalizer pipe connections must be connected between the main

tank and OLTC to avoid buckling of OLTC.
13. The bursting head of explosion vent is to be removed and a
blanking plate fixed before vacuuming the transformer.
14. The required vacuuming
shall be for two hours. Replace vent
explosion head.
15. Oil may be injected through the bottom drain valve into the
transformer. No rubber hoses should be used for filling.
16. Hot oil circulation is to be done to expel moisture from the
insulation at 60-700.
17. Cooler connections must be open for hot oil circulation.
18. Circulation must be continued until no moisture drops are seen
from the filter vacuum exhaust and IR values improve.
19. The status of drying should also confirm the BDV of oil at 60kV/mt
and moisture content at 15 ppm.
20. Fix the arcing horns for the bushings (for 66kv and above) and
adjust.
21. Connect the transformer body earth.
22. Release any trapped air from the bushings, top cover etc.
Here
OTI
= Oil Temperature Indicator
WTI
= Winding Temperature Indicator
OLTC = On Load Tap Changer
BDV = Breakdown voltage
IR
= Insulation Resistance
Transformer Oil Filtration - In Service Transformers - Certain
Points:
1.
Before taking up the filtration the transformer shall be kept idle, at

least for 24 hours, so that the moisture etc., will settle at the
bottom.
2.
All the radiator valves shall be closed after 24 hours idling of the
transformer.
3.
The transformer external surface shall be covered with insulating

material like tarpaulin or with any other insulating material.
4.
The bottom filter valve of the transformer shall be connected to the

inlet of the filter and out let of the filter shall be connected to the top
filter valve of the transformer.
5.
The Transformer oil during the filtration shall be heated to the

temperature of not more than 600 C.
6.
High vacuum (rated vacuum) of 760 mm Hg is to be maintained in

the filter.
7.
After 48 hours of the filtration the inlet and outlet valve connections
of the filter are to be interchanged, i.e. in let to filter from top of the
transformer and outlet of the filter to the bottom of the transformer.
208
Power Division
8.
If required the LV of bushings of the transformer are to be shorted

and three phased 415 Volts supply may be given to HV terminals of
the Transformer so that there is some circulating current in the
primary and secondary of the power transformers to heat up the
winding & core.
9.
During filtration once in four hours the IR Values of the transformer

are to be measured and noted along with oil temperature at the time
of the taking readings.
10. During the filtration the IR values will go down for few days and then
start increasing and attains a value after which there will not be
change in the values even the filtration is continued further.
11. That shows the moisture is eliminated from the transformer oil to the
extent possible.
12.
The open the radiator valves and continue the filtration until the
same ER values are attained.
13.
The BDV of the oils is to be tested and if it is satisfactory other

routine tests on the transformer are to be carried out and
transformer can be taken into service
Vacuum Filtration of Oil:

Vacuum filtration of oil should be done separately at 50-700 C and shall
be terminated on attaining parameters below:
Up to 145 kV60 kV/mt BDV, 20 ppm WC
Up to 245 kV 65 kV/mt BDV, 15 ppm WC
Up to 420 kV
-- 70kV/mt BDV, 15 ppm WC
Where BDV = Breakdown Voltage
WC = Water Content
Vacuum Treatment:
kV
Evacuate &Hold
(Hours)
Standing
Time(Hours)
< 145
12
12
Up to
420
24
48
> 420
36
120
Required Basic Properties of Transformer Oil:

1. High electric strength - to withstand high electric Stresses
2. Sufficient low viscosity - to be able to circulate and to transfer heat
3. Adequate low temperature properties - down to the extreme of
climatic conditions
4. Proper oxidation resistance - to ensure long life
209
Power Division
Main Causes for Deterioration of Oil are:

1. Physical contamination
2. Chemical contamination
3. Contamination by gases
Physical Contamination:
1. Contact with construction particles
2. Fibrous impurities like paper, press board, cotton tapes, rubber etc.
3. Dissolution of varnish (Paint)
4. Moisture by leakage, breathing action, during draining or topping
up operation
5. Chemical reactions etc.
Chemical Contamination:
1. Thermal decomposition
2. Oxidation
3. Catalytic effect of construction metals
4. Reaction of acids with paper and metal parts
5. Sludge
Contamination by Gases:
1. Gases those dissolve in oil from atmosphere
2. Gases those are generated due to various reactions
Tests on Transformer Oil:
A. Physical Tests:
l. Appearance
The oil shall be clear, transparent and free from suspended matter
In appearance if colors of oil is
1. Light - indicates degree of refining
2. Cloudy or foggy - Presence of moisture
3. Greenish tinge - Presence of copper salts
4. Acid smell - Presence of volatile acid can cause corrosion
2. Density: Measured by hydrometer or density bottle varies within
range of 0.85 to 0.89. Higher density results in higher viscosity affects
heat dissipation characteristics of oil
3. Viscosity: Is a measure of its resistance to continuous flow without
the effect of external forces. Prescribes maximum limit 27 CST at 27 C.
Viscosities of lower value is preferred.
4. Pour Point: Is the lowest temperature at which oil will just flow.
indication of minimum temperature of operation.
210
Power Division
An
Pour point below the lowest temperature is preferred 60 C

5. Flash Point: The minimum temperature to which the oil must be
heated to give enough Vapour which can form a combustible mixture
with air.
Flash point of 140 C to 150 C is minimum specified for good oil. Flash
point for oil in use is 125 C minimum. So flash point determines the fire
Hazards.
6. Interface Tension: Is the measure of resultant molecular attractive
force between unlike molecules like water and oil at the interface.
Minimum value 40 dynes/M or 0.04 N/M
For oil in use minimum value is 0.0018 N/M is a measure of contaminants
in oil.
B. Chemical Tests:
1.
Neutralization Number
Is the determination of acidic constituents in the insulating oils.

Limits for fresh oil - 0.03 mg KOH/gm - maximum
Limits for used oil - 0.05 mg KOH/gm - maximum
It leads to formation of sludge, metal surface corrosion and lowering of
dielectric strength.
2. Corrosive Sulphur
It indicates the presence sulphur, sulphur compounds, which are
corrosive in nature and corrode the copper surface.
3. Oxidation Stability
Covers the evaluation of acid and sludge forming tendency of new
mineral oils. For used oil should be minimum to minimize electrical
conduction and corrosion
4. Water Content
By moisture entry into oil.
a. By accidental leakage
b. Breathing action
c. During oil filling or topping up
d. By chemical reaction
In unused oil - Maximum 30 ppm
Oil is in transformer 145 kV & above - Maximum 15 ppm
Oils in transformers 145 kV & below - Maximum 25 ppm
It reduces electrical strength and promotes degradation of oil as well as
paper.
C. Electrical Tests
1. Electrical Strength
211
Power Division
Is the voltage at which arc discharge occurs between two electrodes with
2.5 mm gap. New oil unfiltered - 30 KV minimum (rms) New oil filtered 60 KV minimum (rms)
Before energizing new transformers as per
Below 72.5 kV equipments - 40 kV Mini (rms)
Above 72.5 kV less than 145 kV - 50 KV Minimum (rms)
Above 145 kV - 60 kV Minimum (rms)
2. Dielectric Dissipation Factor (Tan Delta & Loss Tangent)
Dissipation factor: Power loss in dielectric/apparent power (Volt Amp)
Voltage and resulting current deviates from II radians.
Is measure of dielectric losses in oil & hence the amount of heat energy
dissipated.
1. Tan delta at 90 for unused oil - maximum 0.2
2. Tan delta at 90 oil before charging transformer - maximum 0.05
3. Tan delta at 90 for oil above 145 kV - maximum 0.2
4. Tan delta at 90 for oil below 145 kV - maximum 1.0
Low value of tan delta indicates low losses.
3. Resistivity
Provides a sensitive method of determining the conducting impurities. It
affects the electrical losses & causes deterioration of oil equipment
failure.
For unused oil at 27 - 2.5 x 1012 Ohms minimum For unused oil at
90C - 0.02 x 1012 Ohms (minimum) For used oil at 90 C - 0.1 x 1012
Ohms (minimum
Properties of Transformer Oil:
1
Appearance
Acidity (max.)
Clear, transparent and free from

Suspended matter or
sediments
0.03mg of KOH/gm for fresh oil
0.05mg of KOH/gm for used oil
3.
4.
5.
Flash Point (min)
1400 C
Viscosity at -150C
800 centi strokes
Viscosity at 200C
Kinematic Viscosity at 270C
(max)
40 centi strokes
6.
Pour Point (Max)
7.
BDV in 2.5mm gap-new

untreated BDV in 2.5mm
after treatment
27 cSt
-60C
30kV/min
60kV/min
212
Power Division

8.
9
10.
Oil delivered in bulk

Water content in
Transformer(max)
Density at 270C (Max.)
30 to 40 kV/mt
5 ppm
0.89gm/cm cu
11.
Dielectric dissipation factor

Tan at 900 C max.
0.005
12.
Loss Tangent at 200C
0.001
13.
Loss Tangent for Fresh Dry oil

Specific resistance
(resistivity)
14.
0.002 to 0.004
a)
At 90 0C minimum
35 x 10
b)
At 27 0C minimum
1500 x 10
15
Oxidation stability
Neutralization value after
oxidation Max.
Total sledge after oxidation
Max.
Aging characteristic after
accelerated aging
Specific resistance at 27 0C
a)
b)
16
12
ohm cm
12
ohm cm
0.40 mg. KOH/g

0.10 %/Wt..
2.5 x 10
12
ohms-cm (min)
0.2 x 10
ohms-cm (min)
d)
Specific resistance at 90 C
Dielectric dissipation factor
tan at 900 C.
Total Acidity
12
e)
Total Sludge
0.05% by weight (max)
f)
Water content
The oil shall contain
antioxidant additives
50 ppm (max)
a)
b)
c)
g)
0.20 (max)
0.05mg of KOH/gm (max)
213
Power Division
COMPRESSED AIR SYSTEM

Introduction:
Compressed air system in substation is required for the operation of air
blast circuit breakers and pneumatically operated circuit breakers and
disconnector switches. A reliable source of supply of compressed air is
very essential for successful operation of the equipment.
Types of Compressed Air System:
1) Central compressor system
2) Unit compressor receiver system
Central Compressor System:
This arrangement is provided in substations where the number of circuit
breakers to be served is large. The central compressor normally works at
a high pressure and through reducing valves; the pressure is reduced to
a working level at local receiver of each circuit breaker. The valves of
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Power Division
high or low pressure vary from manufacturer to manufacturer. The air

pressure in the receivers of circuit breaker is of the order of 20-30
kgf/cm2 (for 220 kV CBs). The local receivers are of the size that the air
pressure is maintained for 4 to 12 repeated operations. When the
pressure in the receiver of the breaker receiver reduces below a certain
value (say 20 kgf/cm2 the pneumatic valves automatically open and air is
let into the receiver from the compressed air system of a higher pressure
reduces (30 to 40 kgf/cm2) and the pressure in the air receiver is
maintained at the desired. Generally the rated pressure of central air
receiver is kept about twice the rated pressure for breaker operation. The
advantages of choosing high pressure for the central receiver are
a. Ensured availability of working pressure in the circuit breaker
receiver immediately
b. After one specified duty operation.
c. Elimination of moisture in the compressed air, as the expansion
takes place from high pressure in the central receiver to working
pressure in the circuit breaker receiver.
d. Reduction in storage volume.
Usually two identical compressor sets are provided. These are driven by
2 to 2.5 Induction motors. One set is for standby. The compressed air
system consists of Main Air Reservoir, Ring main air pipe line,
compressor and other equipment for measurement and automatic
operation. When the Pressure in the main reservoir reduces below certain
value the compressor motor starts automatically. When the desired
pressure is reached the motor and compressor stops. In the compressed
air system, there are non-.return Valves and a Provision of ring main. The
air is made moisture free by heater and drying chambers in which
moisture absorbing agent like silica gel is kept.
The compressors are installed in compressor room in the back yard. The
main reservoirs of bigger size are installed near the compressor room.
The compressed air piping is taken through trenches. Individual breaker
receivers are connected to this pipe line.
Packaged Compressed Air Equipment:
The compressed air plant is compact, self contained, factory assembled
unit. The plant comprises
Compressor
Dehydrator
High Pressure Air Receiver
Pressure gauges, valves etc.
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Air storage is in bottles kept below the compressor units. Number of

bottles depends on the requirements. Such packaged compressed air
equipment is either one for each breaker or one for a group of breakers.
Unit Compressor Receiver System:
This system may be provided in the substations where the number of
circuit breakers to be served is small. In this arrangement, each circuit
breaker will have its own compressor and receiver. A single compressor is
used but a connector is provided to allow a portable compressor to be
coupled for maintenance or in emergency. In such an arrangement, the
storage capacity of the local receiver should be sufficient for two or three
operations without recharging. The usual practice is that the time to
restore 95% pressure following a breaker operation is 3-5 minutes or
even less.
Pneumatic Operating System:
1. This includes following items:
2. One pneumatically-powered operating mechanism for each pole; the
driving piston is in line with and directly connected to drive rod. This
operating mechanism is highly reliable as its control logic admits
mechanical as well as electrical redundancy.
3. An auxiliary reserve of compressed air stored in the supporting
structure of each single phase unit formed by four steel tubes
mounted on a base frame for anchoring to the foundations; therefore
this structure acts, at the same time, as singlepole support and as
compressed air storage for the driving mechanism operations.
4. One control panel for each three pole breaker, performing all breaker
electric control function and containing the auxiliary equipment.
5. One motor-compressor unit for each three-breaker for an independent
air
compressed air supply to the breakers pneumatic operating
mechanisms where
a centralized compressed air plant exists,
the motor-compressor is replaced by a Pressure reducer.
Compressed Air System for Pneumatic Mechanism:
Pneumatic mechanism is a logical choice for ABCBs because pressurized
air is already used for arc extinction in the breaker. However this
mechanism is not limited to the ABCBs, but is used for oil circuit breakers
and SF6 circuit breakers also.
The pressure of operating air produced by the self enclosed motor
compressor unit is supervised by a pressure gauge and controlled by a
pressure switch. The pressure switch has four sets of contacts each of
which operates at a different pressure level for start/stop, low pressure
indication, reclosure interlock, closing and opening interlock. This type of
interlock is provided for each pole of 420kV and 765 kV CB.
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Power Division
Pneumatic Opening and Pneumatic Closing Mechanism:

Pneumatic mechanism with pneumatic force used both for contact
opening and contact closing operations is also used. The direction is
controlled by activation of the independent opening and closing port of
the three way valves.
Pneumatically Closed Spring Opened Mechanism:
The operating mechanism of a circuit breaker may be of Pneumaticallyclosed spring opened Mechanism. Compressed air at high pressure is
used for closing. High pressure air is stored in the air receiver of the
breaker. While closing the air at high pressure (18-30 kgf/cm 2) is
admitted in the pneumatic cylinder. The closing piston is pushed by
compressed air. There by the levers move and closing operation is
obtained. In addition to closing the contacts, the mechanism charges the
set of opening springs. Once the contacts are closed, a trip latch is
engaged to hold the breaker in a closed position. The automatic
operations are achieved by means of solenoid operated pneumatic
valves
Pneumo - Spring Mechanisms
This type of mechanism is used by large number of manufacturers of SF 6
circuit breakers. In this operating mechanism, a piston is used to drive
the opening linkages and also to charge the closing springs. In order to
close the circuit breaker high pressure air is applied to the underside of
the piston by opening a three way valve; the piston moves downwards
while transmitting the opening force through a toggle arrangement.
Once the contacts open, a close latch is engaged to hold the breaker in
open position. The stored energy of the springs is used for closing the
breaker. Closing is achieved by energizing the closing solenoid, which in
turn releases the closing latch, thus allowing the discharge of the closing
springs, forcing the contacts to the closed position.
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Compressed Air System for Operating Mechanism:
1. 3-stage air cooled reciprocating compressor

2. Motor
3. Air filter
4. After cooler
5. Compressor pressure control
6. Pressure alarm
7. Low pressure switch
8. Pressure gauge
9. Relief Valve
10. Non-return valve
11. Stop valve, normally open
12. Stop valve, normally closed
13. Flow Indicator
Maintenance of Compressed Air System:
The air-blast circuit breakers use fresh compressed air for arc quenching
and do not require maintenance of quenching medium. Only the dryness
of air should be ensured. The compressed air system needs routine
inspection. After specified number of operations, contacts are to be
checked condensate at compressor filter HV receiver, LP piping system
local air receiver must be drained daily to ensure moist free air in control
and extinguishing air insulators and also in interrupters.
The major problem in compressed air system is the leakage from
threaded joint or from mating parts joined by means of nut-bolt. These
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Power Division
parts shall be carefully designed, manufactured and assembled. O-rings

made of good quality neoprene rubber and properly designed grooves for
o-rings reduce the chances of leakage from the static parts. Teflon tapes
can be used over the threaded joints in order to eliminate leakage
through the threads.
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FIRE-FIGHTING SYSTEM
Fire: Fire is defined as the chemical reaction between Fuel and

Oxygen (Air) in presence of Heat
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Classification of Fires:
Fires are mainly classified into A, B, C, D, & E categories as detailed
below:
Class-A: Fires involving ordinary combustible materials such as wood,
paper, coal, cotton, Jute etc.
Class-B: Fires involving inflammable liquids such as petrol, kerosene,
lubricating
oils, diesel, fuel oil, greases, Transformer
oil etc.
Class-C:
Fires involving
Acetylene,
inflammable gasses such

methane, P.G. etc.
Class-D: Fires involving

Magnesium,
combustible metals
Aluminium etc.
such
as
as
hydrogen,
Sodium,
Class -E: Fires involving live electrical equipment

Types of Fire-Fighting Systems:
The objective of fire fighting system shall be to extinguish the fire very
quickly and to prevent the spreading of fire.
Following are different types of Fixed Fire-fighting systems in practice
1. Fire Hydrant system.
2. High Velocity Water Spray System (Emulsifier protection system).
3. Nitrogen injection fire prevention method for transformers only
4. Portable fire extinguishers.
i
CO2 flooding system
ii Foam flooding system.

iii DCP system etc., etc.
Fire Hydrant System:
The Fire Hydrant system comprises of the following:
1. Water storage tank
2. Fire water pump house
3. One Electric motor driven Pump and One Electric motor driven
Pump provided in Fire Water Pump House
4. Piping (under ground and over ground)and connected isolating
valves
5. Hydrant valves
6. Fire hoses
7. Branch pipes with nozzles
8. AC and DC distribution boards in pump house.
9. Control panels, local control panels ,annunciation panels and
cabinets
10.
Cabling
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11.
Safety grounding of electrical equipment
Water Tank Storage Capacity:

The water storage tank shall be made of RCC construction over ground
and shall be in two parts. The storage capacity shall be equal to sum of
the following.
i
One hour pumping capacity of Hydrant System or 135m 3 whichever

is more
ii Half an hour water requirement for single largest risk covered by

HVW Spray system
Fire Detectors:
Types:
a. Ionization type
b. Photo electric type
c. Smoke type
d. Bi-metallic type
e. Linear heat detection type
Ionization type and photo electric type detectors are used in control
room, offices, MCC room, test lab, store, PLCC room, cable vault area.
Smoke type detector is effective for invisible smoke and photo electric
type for visible smoke. Smoke type detectors incorporate LEDs, which
start glowing in the event of fire. Linear heat detection type
detectors
are used in Battery room and AC room areas
Manual call points (Break glass alarm stations) shall be provided at
strategic locations in the control room buildings.
Technical Data of Detectors:
Sl.No
Description
Fixed or
rate of rise
detector
Optical
smoke
detector
Ionization
smoke
detector
Operation voltage
8 to 16 V
7.7 to 10 V
8 to 13 V
Quiescent current
0.4mA
1.2mA
0.1mA
Alarn current
25mA
15mA
25mA
Alarm smoke
concentration
Display
LED red
Temp. Gradient
5oC /min
Release temp.
60oC ,90oC
75oC
Ambient Temp.
(-)20 to
+80oC
(-)20 to
+80oC
30m2
up to
saturation
8
9
Maximum covered
area
3% pm
LED red
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Power Division
LED red
40 to 80m2
limit
10
Maximum Room
height
11
7.5m
12m
12m
Maximum No of
detectors per line
30
30
30
12
Connection cable
2 core
2 core
2 core
13
With break glass

addition
3 core
3 core
3 core
14
Cross section of
cable
1mm2
1mm2
1mm2
Annunciation Panel:
The operation of any of the fire detectors/manual call point shall resulting
the following annunciations / alarms.
1. Visual signal exhibited in the annunciation panels indicating the
area where the fire is detected
2. An audible alarm sound
3. An external audible alarm sounded in the building
4. If the zone comprises more than one ohm a visual signal shall be
exhibited on the outer wall of each room
5. A signal shall be given to Air condition system for its shutdown
Functioning of Hydrant System:

The Fire Hydrant pumps are installed in Fire Water Pump Houses and the
pipe- lines are kept charged under pressure, up to the Hydrant valve. Fire
hoses and branch pipe with nozzle are kept in the Hose Box/Hose
Station installed near the Hydrant valve/location for use in
emergencies. The Hydrant valves have been distributed all over the
plant at strategic locations. In case of fire, the fire hose male coupling
is to be inserted into the Hydrant valve female coupling which will hold
the male coupling by means of a spring lock. Connect any number of
hoses as desired and the branch pipe with nozzle at the end of fire hose
coupling, where the actual usage of water is required. Two persons shall
hold the B.P. nozzle firmly and another person has to open the Hydrant
valve slowly by means of the hand wheel/spanner.
Hydrant System:
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Power Division

HYDRAN VALVE
FIRE HOSE
Hydrant protection shall be provided for the following in the substation.
Control room building
Diesel Generator set building
L T transformer area
Fire Water pump house
Stores
Transformers
Shunt reactors / bus reactors
The parameters of Fire Water Pumps as per Tariff Advisory Committee

Manual are as below.
1. For a total number of hydrants upto 20, one pump of 96 m 2/hr.
capacity with a pressure of 5.6 kg/cm2 (gauge)
2. For a total number of hydrants exceeding 20, upto 55, one pump of
137 m2/hr. capacity with a pressure of 7.0 kg/cm2 (gauge)
3. For a total number of hydrants exceeding 55 ,upto 100, one pump of
171 m2/hr. capacity with a pressure of 7.0 kg/cm2 (gauge)
High Velocity Water Sprays System:
This is also called as Emulsifier Spray Protection System. This type of
protection is provided for the following types of equipment
1. Power transformers
2. Shunt reactors
The Emulsifier spray protection system comprises the following:
1. One Electric motor driven Pump and One diesel engine driven Pump
provided in Fire Water Pump House
2. Piping with connected valves.
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Power Division
3. Deluge valves.
4. Air compressor with connected piping.
5. Heat detectors.
6. Spray nozzles with piping.
The emulsifier pumps are to be installed at cooling water pump house
and the connected piping is to be kept charged under pressure up to
deluge valve. Jockey pump is connected to the emulsifier header to
make up the minor leakages in the system and to maintain the header
pressure constantly at designed value.
A network of heat detectors are to be installed around the equipment,
which is under protection. The system shall be designed such that the
fires are sensed by detectors and the water sprays in that zone
immediately activated.
The detector piping is to be kept charged with air by means of a baby
compressor. Alternate air supply is fed to the baby compressor receiver
tank with a non-return valve from station air compressors to avoid
frequent running of Baby compressors.
In case of fire, the Quartzoid Bulb (glass bulb) detector in the fire zone
will shatter when the temperature in the surrounding area reaches 79 0C
and the air will escape from the differential air chamber resulting in
opening of the deluge valve and releases water spray. The pumps will
automatically come into service and cater to the enhanced water
requirement. Once the fire is extinguished
a The pump has to be manually stopped and normalcy restored.
b The shattered quartzoid (bulb) detector(s) are to be replaced and
air pressure is to be established.
c It must be ensured that the gate valves (before and after the
deluge valve) are in open position.
d The jockey and emulsifier pumps shall be kept in auto mode.
Following are the pressures of running water to be maintained.
1. Minimum pressure of running water at any projector at any
instance: 3.5 Bar
2. Maximum pressure of running water at any projector at any
instance: 3.5 Bar
Following are the discharge densities of water to be maintained
1.
Discharge density on ground surface: 6.1 lpm/m2
2.
Minimum Discharge density on other surface: 10.2 lpm
In case of fire, the Transformers may outburst causing damage to other
substation equipment. The Transformer oil may spread everywhere
causing spreading of fire in the cable trenches besides Emulsifier
protection, the power Transformers in the outdoor switchyard are
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Power Division
provided with barrier walls constructed with refractory bricks of height

covering the bushings. An underground oil sump is provided near the
Transformers at a lower level than the Transformer foundation. The oil
from the Transformer foundation cavity flows in to the sump through a
well designed trench having good gradient and with tile finish. In the
event of fire in the Transformer, the oil from the transformer is drained
quickly in to the sump.
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Power Division
Transformer Emulsifier Spray System:
QUARTZOID BULB
DETECTORS
SPRAY
NOZZLES
ALARAM
GONG BELL
VAL
VE
DELUGE
VALVE
FROM PUMP
HOUSE
The electrical clearances between the emulsifier system pipe work and
live parts of the protected equipment shall not be less than the following:
765 kV bushing
4900mm
420 kV bushing
3500mm
245 kV bushing
2150mm
145 kV bushing
1300mm
52 kV bushing
630mm
36 kV bushing
320mm
Thermo Electric Sprinkler System for Cable Galleries:

Thermo electric sprinkler system can be provided for different cable
galleries of major substations by dividing them into convenient zones
and sub-sections. The flow of water to the cable galleries is controlled
through Installation Control Valves (ICV). Water can be sprayed from
respective emulsifier water spray headers making an inter connection
with hydrant system through NRVA net work of pipes beyond ICVs are
terminated at thermo electric sprinklers located strategically in the cable
galleries. These pipes are designed for achieving necessary pressure at
each sprinkler point Ionization and optical smoke detectors and linear
smoke sensing cable located in cable galleries mounted on ceilings and
cable tray respectively detect fire so that thermo electric sprinklers
operate. The system has to be reset after operation and after fire
quenching is completed.
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Portable Fire Extinguishers

Carbon Dioxide Fire Extinguishers: (CO2 Type):
The CO2 gas under high pressure is stored in cylinders in liquid form,
when operated, CO2 gas is released with force in the form of white fog
and quenches the fire by blanketing, effectively cutting off air supply to
the fire. Big size cylinders are provided with trolley and handle for easy
movement of cylinders in emergencies.
8/9/22.5/45 kgs Capacity CO2 Fire Extinguisher
VALVE HAND WHEEL
CO2 VALVE
CARRYING
HANDLE
DISCHARGE HOSE
HAND GRIP
CYLINDE
R
DISCHARGE HORN
TROLLEY
WHEELS
Mechanical Foam (AFFF) Type Fire Extinguisher:

STRIKING KNOB
SAFETY CLIP
CAP
DISCHARGE
HOSE
CO2 GAS
CARTRIDGE
AFFF
COMPOUND
DISCHARGE
TUBE
FOAM NOZZLE
BODY
Mechanical foam (AFFF) Type Fire Extinguishers are reconnected for use
on class A & B Fires. Aqueous Film Forming Foam Compound (AFFF) is
mixed in water and filled in the cylinder up to the mark. A CO 2 gas
cartridge is fixed to the cap. The discharge hose is provided with a foam
nozzle for delivering the foam.
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Power Division
D.C.P. Type Fire Extinguishers:

Dry Chemical Power type (D.C.P) fire extinguishers are commonly
recommended for fires involving flammable liquids viz., oils, petrol,
paints, varnishes etc. (Class-B Fires), gases (Class - C Fires) viz., LPG,
acetylene, etc., Fires involving live electrical equipment such as cables,
motors, M.C.C.s etc. (Class-E Fires). They can also control small surface
fires in ordinary combustible materials (class-A Fire) viz., wood, paper,
jute, textile etc.
Method of Operation (10 Kgs):
1)
Carry the fire extinguisher to the scene of fire.
2)
Remove the safety clip.
3)
Press the squeeze grip nozzle and strike on the plunger head with
hand piercing the seal of CO2 cartridge fixed to the cap.
4)
The CO2 gas released from the cartridge pressurizes the dry
powder and released as fog from nozzle with force.
5)
Move the nozzle with sweeping action and direct the power at the
base of Fire
10 Kgs. Capacity
D.C.P. Fire Extinguisher:

STRIKING KNOB
SAFETY CLIP
CAP
DISCHARGE HOSE
CO2 GAS
CARTRIDGE
INNERCAGE
SQUEEZE GRIP
NOZZLE
D.C.P
Method of Operation of 75 Kgs. Capacity D.C.P. Fire Extinguisher

(75 Kgs):
a. Move the fire extinguisher to the scene of fire.
b. Un-coil the hose.
c. Open the CO2 cylinder valve slowly.
d. Press the squeeze grip nozzle lever so that DCP is discharged at
the seat of fire.
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Power Division
Technical Particulars for 150kg Capacity DCP Fire Fighting Unit:

1 Extinguishant:
2 Vessel: Dia.
Thickness of plate
Plate material
3 Welding
4 Fittings joint welds

5 Hydraulic pressure
test
6 Cylinder top filler
and bottom drain
7 Discharge pipe
8 Safety valve
9 Manual release
valve
1 Diffuser system
0
1 CO2 cylinders
1
1 Hose
2
1 Discharge control
3 valve
BC dry chemical powder or ABC (Mono

Ammonium Phosphate)
600mm
8mm
Boiler quality steel
Radiographic welding ASME Code shielded inert
gas metal/Tungsten arc welding.10% spot
radiography test covering 50% T-joints
Tested by dye penetrate test
100% at 30kg/cm2 pressure for 5 minutes. No
leak or drop of pressure
Seamless tube, mild steel IS:1239 Part-1 with
bore 75 mm and flanged type.
Seamless tube, mild steel IS:1239 Part-1
Gun metal, spring loaded and set at 25kg/ cm2
Pressure, fitted on to top of vessel
Ball valve fitted onto top of vessel
Gun metal diffuser to burge & fluidize the dry
chemical powder inside the vessel for uniform
and high velocity discharge
2 Nos. 6.8 kg. capacity, with cylinders
conforming to IS:3224
Discharge hose - Markwell R3 hose mounted and
clamped on trailer 25mm bore x 15 m long
braided rubber/Pvc hose of bursting pressure
60kg/cm2 minimum. Hose grounded to body to
avoid static electric charge
Pistol type for easy & controlled operation made
of aluminium alloy IS 617. Nozzle closed with
plastic blow off cap to prevent ingress of
moisture and other foreign material.
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Power Division
1 Trailer
4
RTO approved with MS sections, 2 Nos. 16 X 6

ply tyre & tube and aluminium chequered plate
has roof top to protect vessel.
1 Performance
5 Response time
Discharge
efficiency
Discharge throw
1 Anticorrosive
6 coating Internal
coating
External painting
1 Special features
7
12 sec max
98%min
28 to 30m from end of nozzle
0.18mm thick
Fire red ,0.1 to 0.2 mm thick
Longer throw
Capacity of cylinder is more to handle fires
Suitable for all classes of fire.
Regulatable
Efficiency of extinguishing fire is three times
more than the conventional equipment.
Instrumentation and Control:

Fire protection system should include suitable instrumentation and
necessary controls to render the system efficient and reliable. There
should be local control panels for each of the pumps individually as also
for the operation of deluge valve of the HVW spray system. There should
be a common control panel for the Jockey Pump and Air compressors.
Main annunciation panel should be common control panel for the control
room for the facilities provided in the control room and for repeating
some annunciation from pump house.
The following annunciation is usually provided in the fire water pump
house:
1. Electric motor driven HVW spray pump running/fails to start
2. Diesel engine driven HVW spray pump running/fails to start
3. Hydrant pump running/fails to start.
4. Jockey pump running / fails to start
5. Air compressed fails o start.
6. Hydro-pneumatic tank pressure low
7. Hydro pneumatic tank pressure high
8. System header pressure low
9. Fire in transformer/reactor
10.
Fire in smoke detection system
11.
Water storage tank water level low

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Power Division
12.
High speed diesel oil tank level low.
The following annunciations should be available in the control room also:

1. Fire in transformer/reactor.
2. Hydrant pump/diesel engine operated HVW spray pump in
operation
3. Motor operated HVW spray pump in operation
4. Fire/fault in Z one 1
5. Fire/fault in Zone 2
6. Fire/fault in Zone 3
7. Fire/fault in Zone 4 (depending on the number of zones)
All fire protection equipment should be covered by a regular and strict
maintenance and test routine. The hydrant systems should be checked
every week which may be possible during night shifts. Sprinkler system
should be checked at regular intervals. Portable equipment should be
charged at specified intervals and must be maintained.
Provision should be made to switch off the air conditioning equipment in
case of fire.
Cable entry openings shall be sealed to prevent the spreading of fire.
Hydrant
Certain Fire Prevention Methods:
1. By following good house keeping.
2. By adopting standard operation and maintenance practices.
3. By eliminating/arresting oil leaks & to avoid accumulation in cable
trenches.
4. By eliminating cotton waste or other combustible debris to be
accumulated on power and control cables and other inflammable
materials
5. By arranging periodical cleaning of cable trenches, cable trays
6. By switching off power supply in go-downs and offices, which are
normally kept locked during nights or on holidays to avoid, shortcircuit fires.
7. By eliminating loose contacts (loose wires) and over loading of
circuits.
8. Do not throw lighted cigarette butts indiscriminately. Avoid smoking
near the areas where inflammable oil / gas is stored or handled.
9. Smoking is strictly prohibited in the plant area and also in the
offices.
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10. Do not use bare wires for tapping power from the sockets where two
cables is to be jointed, use proper insulation.
11. Do not handle inflammable oils like kerosene, petrol for cleaning of
the electrical equipments as any sparks coming out, are likely to
cause ignition of the kerosene or petrol.
12. Get familiarized with the locations where fire equipment is installed.
13. Know how to use the above in case of emergency.
14. Ensure fire fighting appliances are kept ready to meet any
emergency.
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LIGHTING
Terms:
Luminous Flux (F)
Luminous Intensity (I)

solid angle.
Illumination (or) Lux (E)
area.
Utilization Factor (U.F)
Depreciation Factor (D.F)
conditions
Radiant energy in the form of waves

radiated per
second from a luminous
body.
Flux emitted by the source per unit
The luminous flux received per unit
Total lumens utilized on working plane
Total lumens radiated by the lamp
Illumination under normal working
Illumination when everything is clear
Maintenance Factor (M.F)
Illumination when everything is clear

Illumination under normal working
conditions
Luminaire
A complete lighting unit; an assemblage

made up of the fixture, trim and the lamp
Reflectance Table
Use this table to approximate the reflectance of various colors and

materials.
Lighting is required in the control room and out door switch yard in the
substations. Lighting is obtained by different types of lamps depending
upon the area to be illuminated and the location (whether indoor or
outdoor) and other factors.
The lighting in the substation includes
a.
Control room lighting
b.
Switch yard lighting

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Power Division
c.
Street lighting
d.
DG set room
e.
Fire fighting pump house
Illumination Levels:
Average
Illumination
Level (Lux)
Limiting Glare
Index
Vertical control panels
200 to 300
19
Rear of control panels
150
19
Control desks
300
19
Switch houses
150
25
ii)
Offices and reception
300
19
iii)
Conference room
300
19
iv)
AC plant/DG set room
150
v)
Cable gallery/floor
vi)
Store room
100
vii)
Battery room
100
Carrier room
300
ix)
Cloak room
100
--
x)
Work shop/Repair bay
300
25
xi)
Test room
450
19
xii)
Corridors
70
16
Outdoor Switch yard
20
xiv)
Main equipment
50
--
xv)
Approach roads, path

ways, car parkings and
other areas
20
--
Sl.N
o.
i)
viii)
xiii)
Particulars
Control room
70
--
The following lamps are generally preferred.

Control room
CFL, Fluorescent Tube
Office room
Store room
Battery room
Toilet
CFL
Main equipment
HPSV, HPMV
Other locations including road
HPSV, HPMV, Fluorescent Tube

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Power Division
Minimum Mounting Heights:

Use of these wattages at lower heights may result in unacceptable glare.
Lumen Output of Lamps:
Sl.N
o.
Lamp Type
Typical Lumen Output
1.
Fluorescent: 18 Watt
1150
2.
Fluorescent: 30 Watt
2400
3.
CFL 36 Watt
3300
4.
CFL 58 Watt
4600
5.
Mercury Vapour: 250 Watt
13700
6.
Mercury Vapour: 400 Watt
24000
7.
High Pressure Sodium: 250 Watt
27500
8.
High Pressure Sodium: 400 Watt
47500
Sl.No.
1
2
3
4
5
6
7
Lamps
36 Watt (fluorescent)
70 Watt
125 to 150 Watt
250 Watt
400 Watt
1000 Watt
1500 Watt
Minimum Mounting
Heights
up to 4 metres
2.5 meters
3.5 meters
5 meters
8 meters
10 meters
12 meters
Conversion Efficiency and Life of Different Types of Lamps:

Conversion Efficiency
(Lumens per Watt)
Life
(Hours)
Mercury Vapour
40 to 60
22000
Fluorescent
64 t0 90
7000 +
90 to 125
25000
Lamp Type
High Pressure
Sodium
237
Power Division
Low Pressure
Sodium
120 to 200
20000
Reflectance Factors:
Area
Air Conditioned Office
Industrial
Ceiling
0.7
Walls
0.5
Floor
0.2
0.5
0.3
0.2
Lighting Transformer:
The lighting load is taken through the lighting Transformer so as to
prevent failure of main AC station supply to different equipment in the
substation in case of any fault in the lighting circuits.
Technical Particulars:
Sl.N
o.
Particulars
Data
1.
Type of transformer
Dry Type Natural Air Cooled
2.
Rating
KVA
3.
Voltage Ratio
415/415 Volts
4.
No. of phases
Three
5.
Frequency
50 Hz
6.
Winding connection
DYn-1
7.
Class of insulation
B-class
8.
Impedance
4%+10%
9.
No. of taps & steps
5,+5%in steps of 2.5%
10.
Ref. Standard
IS:2026
Lighting Calculations:
Interior Lighting:
Step 1: Calculate Room Index (K) = (L x W)/ {Hm (L+W)}
L = Room Length
W = Room Width
Hm = Mounting Height of Fitting (from working plane)
Work Plane = Desk or Bench Height
Step 2: Calculation of utilization factor
Utilization Factor Table:
LOR: 88.1%
SHR NOM 1.75: 1.0
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Power Division
Reflectance
Room Index (K)
Ceiling Wall Floor

0.75
1.00 1.25 1.5 2.0
3.0
4.0
5.0
0.5
0.3
0.2
0.37 0.42 0.46 0.52 0.56
0.59 0.63 0.66
LOR
SHR NOM
SHR MAX
2.5
0.3
Light output ratio for this fitting.

Nominal Spacing to Height ratio.
Used by lighting design software and not
needed for manual calculations.
Step 3: Calculate the number of fittings (N) = (E x A) / (F x UF x LLF)

E = Lux Level Required on Working Plane
A = Area of Room (L x W)
F = Total Flux (Lumens) from all the Lamps in one Fitting
UF = Utilization Factor from the Table for the Fitting to be Used
LLF = Light Loss Factor.
Step 4: Space Height Ratio
Space the number of fittings uniformly around the room drawing
and check the SHR nominal for the fitting. If it has exceeded,
space the fittings to get back to SHR nom.
Step 5: Number of fittings in each axis of the room
Number in Length = (Total L / W)
Number in Width = (Total W / L)
Exterior Lighting:
Step 1: Calculate Luminous Intensity
Luminous intensity (I) = F/(4 3.14)
Where F = luminous flux
Step 2: Total flux along the beam = F
Where = reflection factor
Step 3: Calculate radius of illumination(R) = L tan ( / 2)
where L = height of the lamp
= beam angle
Step 4: Calculate Illuminated Area (A) = R
Step 5: Calculate average luminance ( Eav) = F / A
For design of lighting system the suppliers have developed software
which can be readily used.
Typical design made with the help of Bajaj software.
Illumination for Control House:
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Power Division
220/33 kV Control House has

1.
Control and Relay panel room
2.
PLCC room
3.
Office room
4.
Battery room
5.
Store and pantry room
6.
Toilets
Considerations:
Ceiling Height = 3500mm
Work plane Height = 1000mm
Ceiling Reflectance = 0.8
Wall Reflectance = 0.5
Floor Reflectance = 0.2
Maintenance Factor = 1
The light used for control room is BSM 136
Lamp type : FTL
No. of lamps = 1
Length = 1.244m, Width = 0.163, Height = 0.076
Lumens /lamp = 2425
Lamp Voltage = 36 W
Rated Power = 48 W
Light output ratio = 62%
Control Room Layout:

30320
TOILET
4840 X 2085
2314X
2455
PLCCROOM
4840 X 5770
PANTRY
2296X
2455
10750
STORE
ELECTRICAL CONTROL ROOM

19720 X 9770
4840 X 4770
BATTERY ROOM
4840 X 4000
OFFICE
Lighting Provide for the Control Room:

Sl.
No.
Area
Length
(mm)
Width
(mm)
240
Power Division
Light
Requir
ed
Lux
Estimate
d
Luminair
es

1
2
3
4
5
6
7
Control & Relay Panel

Room
PLCC Room
Office Room
Battery Room
Store Room
Pantry Room
Toilets
19720
4840
4840
4840
2314
2296
4840
9770
5770
4770
4000
2455
2455
2085
BSM136
BSM136
BSM136
BSM136
BSM136
BSM136
BSM136
300
300
300
100
100
100
100
Total number of Lights (BSM136) required for the control room = 54

Lights (BSM136) required in the corridors = 2
Total Power consumed for the Control Room Illumination
= No of lights x Rated Power
= 56 x 48W
= 2688W
Luminaire for Control Room:
Control and Relay Panel Room: (19720X9770) mm
Illumination for 220/33 kV Outdoor Substation:

Exterior Lighting Design:
Fixed Inputs
Switchyard length
Switchyard width
Work plane height
Hw
lux
Hm
Lux to be maintained
Variable inputs
Height of the l.m/tower
Light output ratio
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Power Division
36
7
6
2
1
1
1

Distance to first luminaire
Lumen output per lamp
lm
Lamp wattage
watts
Rated power
watts
Luminaire efficiency
Luminaire arrangement
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Power Division
Arrows showing the direction of lights which are fixed on the tower
4000
2500
18000
18000
4500
4500
4500
4500
18000
11300
4 5 0 0 15 0 0 4 0 0 0 4 0 0 0 3 0 0 0 4 5 0 0
7000
9500
4500
4 5 0 0 4 5 0 0 15 0 0 4 5 0 0
44000
30320
ELECTRICAL CONTROL ROOM
4840 X 4770
OFFICE
4500
4500
4500
PLCCROOM
4840 X 5770
PANTRY
2296 X
2 455
1075 0
2314X
245 5
4500
5000
TOILET
4840 X
2 085
STORE
4500 2 5 0 0 4500 4500

14 4600
80000
10 0000
4500
5000
1 7 5 03 0 0 01 7 5 20 2 0 20 5 0 20 0 0 20 2 07 05 07 5 10 5 0105 07 05 07 5 02 2 0 20 0 0 03 0 0 0 3 0 0 0
5000
1000 0
5000 3000 5500
6000
BATTERY ROOM
4840 X 4000
7000
5000
1000
3000 2000 3000

66600
1000
60500
135000
240
Power Division
AIR CONDITIONING & VENTILATION SYSTEM

Introduction:
The Air conditioning system shall provide specified environmental
condition for equipment and/or personal during all modes of plant
operation. Filtering, cooling, heating, humidification/dehumidification of
the supply air and its distribution shall be done to maintain the specified
conditions with in the specified limits.
Refrigeration Cycle:
In the refrigeration cycle, a heat pump transfers heat from a lower

temperature heat source into a higher temperature heat sink. Heat would
naturally flow in the opposite direction. This is the most common type of
air conditioning. A refrigerator works in much the same way, as it pumps
the heat out of the interior into the room in which it stands. This cycle
takes advantage of the universal gas law.
PV = nRT,
where P is pressure, V is volume, R is the universal gas constant, T is
temperature, and n is the number of moles of gas (1 mole = 6.0221023
molecules).
The most common refrigeration cycle uses an electric motor to drive a
compressor. Since evaporation occurs when heat is absorbed, and
condensation occurs when heat is released, air conditioners are designed
to use a compressor to cause pressure changes between two
compartments, and actively condense and pump a refrigerant around. A
refrigerant is pumped into the cooled compartment (the evaporator coil),
where the low pressure and low temperature cause the refrigerant to
evaporate into a vapor, taking heat with it. In the other compartment
(the condenser), the refrigerant vapor is compressed and forced through
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Power Division
another heat exchange coil, condensing into a liquid, rejecting the heat
previously absorbed from the cooled space.
Humidity:
Refrigeration air conditioning equipment usually reduces the humidity of
the air processed by the system. The relatively cold (below the dew
point) evaporator coil condenses water vapor from the processed air,
(much like an ice cold drink will condense water on the outside of a
glass), sending the water to a drain and removing water vapor from the
cooled space and lowering the relative humidity. Since humans perspire
to provide natural cooling by the evaporation of perspiration from the
skin, drier air (up to a point) improves the comfort provided. The comfort
air conditioner is designed to create a 40% to 60% relative humidity in
the occupied space.
Some air conditioning units dry the air without cooling it. They work like
a normal air conditioner, except that a heat exchanger is placed between
the intake and exhaust. In combination with convection fans they
achieve a similar level of comfort as an air cooler in humid tropical
climates, but only consume about 1/3 of the electricity. They are also
preferred by those who find the draft created by air coolers
uncomfortable.
Refrigerants:
"Freon" is a trade name for a family of haloalkane refrigerants
manufactured by DuPont and other companies. These refrigerants were
commonly used due to their superior stability and safety properties.
Unfortunately, evidence has accumulated that these chlorine bearing
refrigerants reach the upper atmosphere when they escape. The
chemistry is poorly understood but general consensus seems to be that
CFCs break up in the stratosphere due to UV-radiation, releasing their
chlorine atoms. These chlorine atoms act as catalysts in the breakdown
of ozone, which does severe damage to the ozone layer that shields the
Earth's surface from the strong UV radiation. The chlorine will remain
active as a catalyst until and unless it binds with another particle forming
a stable molecule. CFC refrigerants in common but receding usage
include R-11 and R-12. Newer and more environmentally-safe
refrigerants include HCFCs (R-22, used in most homes today) and HFCs
(R-134a, used in most cars) have replaced most CFC use. HCFCs in turn
are being phased out under the Montreal Protocol and replaced by hydro
fluorocarbons (HFCs), such as R-410A, which lack chlorine.
Types of Air Conditioner Equipment
Window and through-wall units
Window and through-wall units have vents on both the inside and
outside, so inside air to be cooled can be blown in and out by a fan in the
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Power Division
unit, and outside air can also be blown in and out by another fan to act
as the heat sink. The controls are on the inside.
A large house or building may have several such units. Should virtually
every room be cooled with its own air conditioning unit, most of the day,
it would be less expensive to use central air conditioning, though that
may not be physically possible.
Evaporative Coolers:
In very dry climates, evaporative coolers (or "swamp coolers") are
popular for improving comfort during hot weather. This type of cooler is
the dominant cooler used in Iran which has the largest number of units of
any country in the world, hence some referring to them as Persian
coolers. An evaporative cooler is a device that draws outside air through
a wet pad, such as a large sponge soaked with water. The sensible heat
of the incoming air, as measured by a dry bulb thermometer, is reduced.
The total heat (sensible heat plus latent heat) of the entering air is
unchanged. Some of the sensible heat of the entering air is converted to
latent heat by the evaporation of water in the wet cooler pads. If the
entering air is dry enough, the results can be quite comfortable. These
coolers cost less and are mechanically simple to understand and
maintain.
There is a related, more complex process called absorptive
refrigeration which uses heat to produce cooling. In one instance, a
three-stage absorptive cooler first dehumidifies the air with a spray of
salt-water or brine. The brine osmotically absorbs water vapor from the
air. The second stage sprays water in the air, cooling the air by
evaporation. Finally, to control the humidity, the air passes through
another brine spray. The brine is reconcentrated by distillation. The
system is used in some hospitals because, with filtering, a sufficiently hot
regenerative distillation removes airborne organisms.
Absorptive chillers:
Some buildings use gas turbines to generate electricity. The exhausts of
these are hot enough to drive an absorptive chiller that produces cold
water. The cold water is then run through radiators in air ducts for
hydronic cooling. The dual use of the energy, both to generate electricity
and cooling, makes this technology attractive when regional utility and
fuel prices are right. Producing heat, power, and cooling in one system is
known as tri-generation.
Chilled-water and Cooling-tower AC Units
In a chilled-water system, the entire air conditioner lives on the roof or
behind the building. It cools water to between 40 and 45 F (4.4 and 7.2
C). This chilled water is then piped throughout the building and
connected to air handlers as needed. There is no practical limit to the
length of a chilled-water pipe if it is well-insulated.
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Power Division
You can see in this diagram that the air conditioner (on the left) is
completely standard. The heat exchanger lets the cold Freon chill the
water that runs throughout the building.
Cooling Towers
In all of the systems described earlier, air is used to dissipate the heat
from the outside coil. In large systems, the efficiency can be improved
significantly by using a cooling tower. The cooling tower creates a
stream of lower-temperature water. This water runs through a heat
exchanger and cools the hot coils of the air conditioner unit. It costs
more to buy the system initially, but the energy savings can be
significant over time (especially in areas with low humidity), so the
system pays for itself fairly quickly.
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Cooling towers come in all shapes and sizes. They all work on the same
principle:
1. A cooling tower blows air through a stream of water so that some
of the water evaporates.
2. Generally, the water trickles through a thick sheet of open plastic
mesh.
3. Air blows through the mesh at right angles to the water flow.
4. The evaporation cools the stream of water.
5. Because some of the water is lost to evaporation, the cooling
tower constantly adds water to the system to make up the
difference.
The amount of cooling that you get from a cooling tower depends on the
relative humidity of the air and the barometric pressure.
For example, assuming a 950 F (350C) day, barometric pressure of
29.92 inches (sea-level normal pressure) and 80-percent humidity, the
temperature of the water in the cooling tower will drop about 6 degrees
to 890 F (3.360 to 31.7 C).
If the humidity is 50 percent, then the water temperature will drop
perhaps 150 to 800 F (8.40 to 26.7 0C).
If the humidity is 20 percent, then the water temperature will drop
about
28 0 to 670 F (15.70 to 19.40C). Even small temperature drops
can have a significant effect on energy consumption.
Whenever you walk behind a building and find a unit that has large
quantities of water running through a plastic mesh, you will know you
have found a cooling tower.
In many office complexes and college campuses, cooling towers and
air conditioning equipment are centralized, and chilled water is routed to
all of the buildings through miles of underground pipes.
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Power Division
Split-system AC Units:
A split-system air conditioner splits the hot air from the cold side of
the system, like this:
The
cold side,
consisting of the expansion valve and the cold coil, is generally placed
into a furnace or some other air handler. The air handler blows air
through the coil and routes the air throughout the building using a series
of ducts. The hot side, known as the condensing unit, lives outside the
building. In most home installations, the unit looks something like this:
The unit consists of a long, spiral coil shaped like a cylinder. Inside the
coil is a fan, to blow air through the coil, along with a weatherresistant compressor and some control logic. This approach has
evolved over the years because it is low-cost and also because it
normally results in reduced noise inside the house (at the expense of
increased noise outside the house). Besides the fact that the hot and
cold sides are split apart and the capacity is higher (making the coils and
compressor larger), there is no difference between a split-system and a
window air conditioner.
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Energy Efficient Cooling Systems:

Because of the rising costs of electricity and a growing trend to "go
green," more people are turning to alternative cooling methods to spare
their pocketbooks and the environment. Big businesses are even jumping
on board in an effort to improve their public image and lower their
overhead.
Ice cooling systems are one way that businesses are combating high
electricity costs during the summer. Ice cooling is as simple as it sounds.
Large tanks of water freeze into ice at night, when energy demands are
lower. The next day, a system much like a conventional air conditioner
pumps the cool air from the ice into the building. Ice cooling saves
money, cuts pollution, eases the strain on the power grid and can be
used alongside traditional systems. The downside of ice cooling is that
the systems are expensive to install and require a lot of space. Even with
the high startup costs, more than 3,000 systems are in use worldwide?
An ice cooling system is a great way to save money and conserve
energy, but its price tag and space requirements limit it to large
buildings. One way that homeowners can save on energy costs are by
installing geo-thermal heating and cooling systems, also known as
ground source heat pumps (GSHP). The Environmental Protection Agency
recently named geo-thermal units "the most energy-efficient and
environmentally sensitive of all space conditioning systems."
Although it varies, at six feet underground the Earth's temperatures
range from 45 F to 75 F. The basic principle behind geo-thermal cooling is
to use this constant temperature as a heat source instead of generating
heat with electricity.
The most common type of geo-thermal unit for homes is the closedloop system. Polyethylene pipes are buried under the ground, either
vertically like a well or horizontally in three- to six-foot trenches. They
can also be buried under ponds. Water or an anti-freeze/water mixture is
pumped through the pipes. During the winter, the fluid collects heat from
the earth and carries it through the system and into the building. During
the summer, the system reverses itself to cool the building by pulling
heat from the building, carrying it through the system and placing it in
the ground.
Homeowners can save 30 to 50 percent on their cooling bills by
replacing their traditional HVAC systems with ground source heat pumps.
The initial costs can be up to 30 percent more, but that money can be
recouped in three to five years, and most states offer financial purchase
incentives. Another benefit is that the system lasts longer than
traditional units because it's protected from the elements and immune to
theft.
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Power Division
Passive Cooling: Some people go to the extreme and get rid of their AC
units entirely. Passive cooling is the greenest of trends and a great way
to save money. Passive cooling revolves around the concept of removing
warm air from your home using the interaction between the house and
its surroundings. There are several ways to block and remove heat,
including shading through landscaping, using a dark exterior paint,
installing a radiant barrier in the roof rafters and good old- fashioned
insulation. Another way is through thermal siphoning, the process of
removing heat through controlled airflow. Opening the lower windows on
the breezy side of your house and the upper windows on the opposite
side creates a vacuum that draws out the hot air. Ceiling fans and roof
vents are other ways to direct heat out at low cost
Central Air Conditioning: With a typical split system, the condenser
and compressor are located in an outdoor unit; the evaporator is
mounted in the air handling unit (which is often a forced air
furnace). With a package system, all components are located in a
single outdoor unit that may be Central air conditioning, commonly
referred to as central air (US) or air-con (UK), is an air conditioning
system which uses ducts to distribute cooled and/or dehumidified
air to more than one room, or uses pipes to distribute chilled water
to heat exchangers in more than one room, and which is not
plugged into a standard electrical outlet located on the ground or
roof.
Central air conditioning performs like a regular air conditioner but has
several added benefits:
When the air handling unit turns on, room air is drawn in from
various parts of the building through return-air ducts. This air is
pulled through a filter where airborne particles such as dust and lint
are removed. Sophisticated filters may remove microscopic
pollutants as well. The filtered air is routed to air supply ductwork
that carries it back to rooms. Whenever the air conditioner is
running, this cycle repeats continually.
Because the central air conditioning unit is located outside the

home, it offers a lower level of noise indoors than a free-standing air
conditioning unit.
Thermostats:
Thermostats control the operation of HVAC systems, turning on the
heating or cooling systems to bring the building to the set temperature.
Typically the heating and cooling systems have separate control systems
(even though they may share a thermostat) so that the temperature is
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Power Division
only controlled "one-way". That is, in winter, a building that is too hot will
not be cooled by the thermostat. Thermostats may also be incorporated
into facility energy management systems in which the power utility
customer may control the overall energy expenditure. In addition, a
growing number of power utilities have made available a device which,
when professionally installed, will control or limit the power to an HVAC
system during peak use times in order to avoid necessitating the use of
rolling blackouts. The customer is given a credit of some sort in
exchange, so it is often to the advantage of the consumer to buy the
most efficient thermostat possible.
Equipment capacity:
Air conditioner equipment power is often described in terms of "tons of
refrige-ration". A "ton of refrigeration" is defined as the cooling power of
one short ton (2000 pounds or 907 kilograms) of ice melting in a 24-hour
period. This is equal to 12,000 per hour, BTU or 3517 watts). Residential
"central air" systems are usually from 1 to 5 tons (3 to 20 kW) in
capacity.
Air conditioners (for cooling) and heat pumps (for heating) both work
similarly in that heat is transferred or "pumped" from a cooler "heatsource" to a warmer "heat-sink". Air conditioners and heat pumps usually
operate most effectively at temperatures around 50 to 55F (1013C).
A 'balance point' is reached when the heat source temperature falls
below about 40F (4C), and the system is not able to pull any more heat
from the heat-source. (This point varies from heat pump to heat pump).
Similarly, when the heat-sink temperature rises to about 120F (49C),
the system will operate less effectively, and will not be able to 'push' out
any more heat. Ground-source (geothermal) heat pumps do not have this
problem of reaching a balance point because they use the ground as a
heat source/heat sink and the ground's thermal inertia prevents it from
becoming too cold or too warm when moving heat from or to it. The
ground's temperature does not vary nearly as much over a year as the
air above it does.
Insulation:
Insulation reduces the required power of the air conditioning system.
Thick walls, reflective roofing material, curtains, and trees next to
buildings also cut down on system and energy requirements.
Air Conditioning in Control Room:
The following areas are generally covered for air conditioning
i
ii
iii
iv
Control room area

PLCC room
Test lab
Conference room/office room area
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Power Division
v Battery area
Technical Data:
Sl.N
o.
1.
2.
Particulars
Capacity in TR
4.
Cubic feet. per

minute
(CFM)
Type of
compressors
Condenser
5.
Air handling fan
6.
8.
Type of filter for

each unit
Cooling coil
i) Type
ii) Material
iii) Fin material
Refrigerant piping
9.
Vibration isolator
3.
7.
Data
10. Condensate trays

11. Controls and
interlocks
12. Noise level
hermetic/scroll type
Air-cooled made of copper tubes with
external fins
Centrifugal fan with belt drive and electric
motor
Pre filter of Fabric type at the outlet
Direct expansion(DX)
Copper
Aluminium
Copper(heavy
gauge)to
IS:2501
or
IS:1239 heavy class seamless MS pipe
with thermostatic expansion valve, liquid
line shutoff valve., high and low pressure
gauges
Six 25mm thick neoprene rubber pads
Made of corrosion resistant material or
treated with corrosion resistant coating
i) Failure of any equipment of the unit
shall trip that conditioning unit
ii) HP and LP cutout shall be provided for
compressor protection. A thermostat
with adjustable setting shall be
provided in the return air circuit to
control the room temperature by ONOFF mode.
iii) A selector switch to enable the
operation of air handling fan alone or
fan with cooling shall be provided
iv) Provision for manual re-starting and
stopping of the compressor
v) Inter lock to start compressor only
after starting the air handling fan.
vi) Interlock to stop the compressor when
condenser fan stops
vii) The humidist shall be interlocked
with re-heater
70 db
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Power Division
13. Accessories
i) Humidifier
ii) Humidistat
iii) Electric strip
heater
14. Thermal Insulation
1).Material
Code
Thermal
conductivity
Density-min.
2)Material
Code
Thermal
conductivity
Density-min.
3)Material
Code
Thermal
conductivity
Density-min.
15. Acoustic insulation
For AHU room
&duct
Material
Density
16. Insulation surface
Supply air duct and
Acoustic insulation
duct
Material
Thickness
AHU drain pipe
Material Thickness
Resin bonded glass wool

IS:8183l
0.49 mw/cm at 500 C
24 kg/cu.m
Mineral wool pipe section Min.Gr.2
IS-9842
0.43 mw/cm at 500C
81 kg/cu.m
Expanded polystyrene
IS-4671
0.37 mw/cm at 100C
15 kg/cu.m

48 kg/cu.m

25mm
Expanded polystyrene mineral wool, Type2 of IS:4671,self extinguishing type
25mm
Calculating Heat Load:

The amount of heat generated is known as the heat gain or heat load.
Heat is measured in either British Thermal Units (BTU) or Kilowatts (KW).
1KW is equivalent to 3412BTUs.
The heat load depends on a number of factors, by taking into account
those that apply in your circumstances and adding them together a
reasonably accurate measure of the total heat can be calculated.
Factors include:
The floor area of the room.
The size and position of windows, and whether they have blinds or
shades.
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Power Division
The number of room occupants (if any).
The heat generated by equipment.
The heat generated by lighting.
Floor Area of Room:

The amount of cooling required depends on the area of the room. To
calculate the area in square meters:
Room Area BTU = Length (m) x Width (m) x 337
Window Size and Position:
If, as is quite common, your Server Room has no windows, you can
ignore this part of the calculation. If, however there are windows you
need to take the size and orientation into account.
South Window BTU = South Facing window Length (m) x Width (m) x 870
North Window BTU = North Facing windows Length (m) x Width (m) x 165
If there are no blinds on the windows multiply the result(s) by 1.5.
Obviously if you are in the Southern Hemisphere you would swap the
conversion factors as the heat on north facing windows is then greatest.
Add together all the BTUs for the windows.
Windows BTU = South Window(s) BTU + North Window(s) BTU
Occupants:
Purpose built Server Rooms doesnt normally have people working in
them, but if people do regularly work in your Server Room you will have
to take that into account. The heat output is around 400 BTU per person.
Total Occupant BTU = Number of occupants x 400
Equipment:
Clearly most heat in a Server Room is generated by the equipment. This
is trickier to calculate that you might think. The wattage on equipment is
the maximum power consumption rating; the actual power consumed
may be less. However it is probably safer to overestimate the wattage
than underestimate it.
Add together all the wattages for Servers, Switches, and Routers and
multiply by 3.5.
Equipment BTU = Total wattage for all equipment x 3.5
Lighting:
Take the total wattage of the lighting and multiply by 4.25.
Lighting BTU = Total wattage for all lighting x 4.25
252
Power Division
Total Cooling Required:

Add all the BTUs together.
Total Heat Load = Room Area BTU + Windows BTU + Total Occupant BTU
+ Equipment BTU + Lighting BTU
This is the amount of cooling required so you need one or more air
conditioning units to handle that amount of heat.
Size of Unit:
Small air conditioning units have a cooling capacity of between 5000 and
10000 BTUs. Small units may fit in windows, venting to the outside
world. Larger units may be rated in tons of cooling. 1 ton of cooling is
equivalent to 12 thousand BTUs.
Ventilation System:
Exhaust fans of propeller type/axial type shall be provided for the rooms
which are not air conditioned complete with suitable drive motors, DOL
starters, rain protection cowl with screen, grounding bolts etc. These
shall be fed from a local distribution board. The schedule of wall mounted
Ventilation/exhaust fans are as mentioned below:
Sl.N
o.
1
2
2
3
4
5
6
Location
Cable Vault
Battery Room
MCC Room
Office room/
Auxiliary building
Store room
Toilets
Pantry/Guest
house
3000
2000
2000
Static
Pressure(m
m mg)
15
10
10
1500
1500
1000
5
5
5
1
1
3
500
Capacity(eac
h)
Quantity
Nos.
5
2
2
It is necessary to ensure sufficient air inlet to the battery room by

providing blowers if necessary. Exhaust alone without air inlet, a negative
pressure will be created in the battery room which causes:
a) Evaporation of electrolyte even at normal room temperature and
the fine spray of electrolyte will settle on cells, stands etc; reducing
the electrical insulation of the battery room ground.
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Power Division
b) The hydrogen evolved from the battery may form an explosive

mixture if the room temperature has reduced.
Important Guide Lines:
CT & VT Earthing
CT/VT secondary neutrals should be earthed at one point only.
VT secondary neutral earthing is done at equipment itself.
It is preferable to earth the CT secondary neutral in the
control/protection cubicle in order to provide maximum security to
the operating personnel.
CT POLARITY
As a practice the P1 terminal of the CT shall be towards the bus
and P2 away from the bus.
254
Power Division
POWER AND CONTROL CABLES

Types of Cables:
1. Aluminum conductor XLPE armoured cable
2. Aluminum PVC insulated armoured cables
Selection of Power and Control Cables:
Power Cables:
Aluminium conductor XLPE insulated armoured cables:
1. From LT Auxiliary Transformer to Distribution board sin Control
room and
2. From Distribution board to colony lighting.
Aluminium conductor PVC insulated armoured cables:
1. Outdoor yard lighting and
2. Control room and other buildings in the substation area.
Control Cables:
For control, protection and instrumentation PVC insulated armoured
control cables of with minimum 2.5 sq, mm size stranded copper
conductors
Storage and Handling of Cable Drums:
Cable drums shall be unloaded, handled and stored in an approved
manner and rolling of drums shall be avoided as far as practicable. For
short distances, the drums may be rolled provided they are rolled slowly
and in proper direction as marked on the drum. In absence of any
indication, the drums may be rolled in the same direction as in was rolled
during taking up the cables.
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Power Division
Power Cables Generally Used for Different Applications:

Sl.No
.
From
To
Cable size
Cable
Insulatio
n
2-1C x 630 mm2 per

phase
1-1C x 630 mm2
2-3 C x300 mm2
XLPE
1-3 C x300 mm2
XLPE
1-3 C x300 mm2
XLPE
Colony lighting
1-3 C x300 mm2
XLPE
HVW pump LCP
1-3 C x300 mm2
XLPE
Lighting
Transformer
Main Lighting
Distribution Board
DG Set AMF panel
1-3 C x300 mm2
XLPE
1-3 C x300 mm2
XLPE
1-3 C x 70 mm2
XLPE
AC Distribution
Board
AC Distribution
Board
Emergency lighting
Transformer
ICT MB
1-3 C x 70 mm2
PVC
1-3 C x 70 mm2
PVC
Bay MB
1-3 C x 35mm2
PVC
13.
AC Distribution
Board
Emergency
lighting
Transformer
Emergency Lighting
DB
1-3 C x 70 mm2
PVC
14.
DCDB
Battery
2-1C x 150 mm2
PVC
15.
DCDB
Battery Charger
2-1C x 150 mm2
PVC
16.
DCDB
2-1C x 150 mm2
PVC
17.
Main Lighting
Distribution
Board
Protection / PLCC
panel
Lighting
Panels(Indoor)
1-3 C x 35mm2
PVC
18.
Main Lighting
Distribution
Board
Lighting
Panels(outdoor)
1-3 C x 70mm2
PVC
19.
Main Lighting
Distribution
Board
Receptacles(Indoor)
1-3 C x 35mm2
PVC
20.
Main Lighting
Distribution
Board
Lighting
Panels(outdoor)
1-3 C x 35mm2
PVC
1.
Main Switch
Board
LT Transformer
2.
Main Switch
Board
Main Switch
Board
Main Switch
Board
Main Switch
Board
Main Switch
Board
Main Switch
Board
Lighting
Transformer
AC Distribution
Board
AC Distribution
Board
Air Conditioning
Board
Oil filtration unit
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
256
Power Division
XLPE

21.
Main Lighting
Distribution
Board
Lighting Panels
1-3 C x 70mm2
PVC
22.
Lighting Panel
Street lighting Poles
1-4C x16 mm2
PVC
23.
Lighting Panel
Lighting fixtures
(outdoor)
1-2C x 6 mm2
PVC
24.
Bay MB
Equipments
PVC
25.
Air Conditioning Board

A/C Unit Panel
1-4C x16 mm2

1-4C x6 mm2
1-2C x 6 mm2
1-3 C x 70 mm2
AHU
1-3 C x 35 mm2
PVC
Heater
1-3 C x 35 mm2
PVC
Chiller Pump
1-3 C x 35 mm2
PVC
26.
27.
28.
PVC
1) The cables shall conform to the standards specified.

2) The design and workmanship shall be in accordance with the best
engineering practices to ensure satisfactory performance throughout
the service life.
All types and sizes of cables must have been type tested. The cables
shall be subjected to routine and acceptance tests in accordance with
the requirements.
Cable Trays and Accessories:
a) The cable trays, fittings (e.g. elbow, reducers, tees etc.,) and
accessories (e.g. side coupler plates etc.) shall be fabricated out of
mild steel sheets free from flaws and conforming to the IS: 226. The
cable trays fittings, accessories and all hardware (i.e. bolts, nuts,
screws, washers etc.) shall be hot dip galvanised as per IS: 2629.
b) Cable trays/supports shall include all necessary coupler plates bolts,
nuts, screws, washers, earth flat running along the cable
supports/trays and any other sundry material required to make the
installation complete.
Conduits, Pipes and Accessories:
1. All rigid conduits, mild steel pipes, flexible conduits, hume pipes etc.
shall be complete with all necessary sundry materials, such as
tees, elbows, check nuts, bushings, reducers, enlargers, wooden
plugs, coupling caps, nipples, gland sealing fittings, pull boxes etc.
These shall be covered in the bid price. The size of the conduit/pipe
shall be selected on the basis of maximum 40% fill criterion.
2. All conduits/pipes shall have their ends closed by caps until cables
are pulled. After cables are pulled, the ends of conduits/pipes shall
257
Power Division
be sealed in an approved manner, to prevent damage to threaded

portions and entrance of moisture and foreign material.
3. Rigid conduits shall be flow-coat metal conduits of reputed make.
The outer surface of the conduits shall be coated with hot-dip zinc
and chromate coatings. The inner surface shall have silicon epoxy
ester coating for easy cable pulling. Mild steel pipes shall be hot dip
galvanised. All rigid conduits/pipes shall be of a reputed make and
threaded portion shall be 'zinc-rich' painted after threading during
installation. The hume-pipes and accessories shall be of reinforced
concrete conforming to class NP 2 of IS: 458. All tests on hume-pipes
shall be done as per IS: 458.
4. Flexible conduits shall be of heat-resistant lead coated steel, water
leak, fire and rust proof and of reputed make.
Junction Boxes:
1. Junction boxes shall be complete with terminals as required. The
brackets, bolts, nuts and screws required for the erection shall be
included in the installation price.
2. The junction boxes shall be fabricated out of CRCA sheet steel of 2
mm thickness. The junction boxes shall be duly galvanised. The
cover shall be provided with a suitable neoprene rubber gasket. The
junction boxes shall be provided with four knock-out plates for
cable/conduit connection and a weeping hole at the bottom plate.
Junction boxes shall be provided with two earthing terminals suitable
for GI earthing strips. Junction boxes shall have IP 54 enclosure as
per IS: 2147.
3. All the terminal blocks shall be rated for 1100V and 15A. These shall
be of clip on type. Each terminal shall be suitable for connecting 2
Nos. 2.5 sq.mm copper conductors. All the terminals shall be
complete with insulated barriers, terminal studs, washers, nuts,
locknuts, identification strips etc.
4. The terminal blocks shall be of reputed make.
Cable Tags and Markers:
1. Each cable and conduit run shall be tagged with numbers that
appear in the cable and conduit schedule.
2. The tag shall be of aluminum with the number punched on it and
securely attached to the cable conduit by not less than two turns of
20 SWG wire conforming to IS: 280. Cable tags shall be of
rectangular shape for power cables and of circular shape for control
cables.
3. Location of cables laid directly underground shall be clearly
258
Power Division
indicated with cable marker made of galvanised iron plate.

4. Location of underground cable joints shall be indicated with cable
marker with an additional inscription "Cable joint".
5. The marker shall project 150 mm above ground and shall be spaced
at an interval of 30 meters and at every change in direction. They
shall be located on both sides of road and drain crossing.
6. Cable tags shall be provided on all cables at each end (just before
entering the equipment enclosure), on both sides of a wall or floor
crossing, on each duct/conduit entry, and at each end and turning
point in cable tray/trench runs. Cable tags shall be provided inside
the switchgear, motor control centers, control and relay panels etc.,
wherever required for cable identification, such as where a number
of cables enter together through a gland plate.
7. The price of cable tags and markers shall be included in the
installation rates for cables/conduits quoted by the Bidder.
Cable Glands:
1.
Double compression type tinned/nickel plated (coating thickness

not less than 20 microns in case of tin and 10 to 15 microns in case
of nickel) brass cable glands shall be provided by the Contractor for
all power and control cables to provide dust and weather proof
terminations. The cable glands shall be tested as per BS: 6121.
They shall comprise of heavy-duty brass casting, machine finished
and tinned or nickel plated to avoid corrosion and oxidation.
Rubber components used in cable gland shall be neoprene and
have tested quality. The maximum and minimum overall diameter
and diameter under armour of the cables, shall be furnished to the
successful bidder. Cable gland shall be suitable for the Purchaser's
cable. The cable glands shall be of reputed make.
2.
The cable glands shall also be tested for dust proof and
weatherproof termination. The test procedure has to be discussed
and agreed to between the Purchaser and cable glands
manufacturer.
Cable Lugs:
1.
Cable lugs shall be tinned copper solder less crimping type

conforming to IS: 8309 and 8394 suitable for aluminum or copper
conductor (as applicable). Solder less crimping of terminals shall be
done by using corrosion inhibitory compound. The cable lugs shall
suit the type of terminals provided on the equipment.
2.
The cable lugs shall be of Dowell make or equivalent.
3.
Crimping tool used shall be of reputed and standard make.
4.
Cable Supports and Cable Tray Mounting Arrangements:

259
Power Division
5.
Contractor will provide embedded steel inserts on concrete

floors/walls and secure supports by welding to these inserts or
available building steel structures.
6.
However, in cases where no such embedded steel inserts are

available; the contractor shall have to secure the supports on walls
or floors by suitable anchoring.
7.
The supports shall be fabricated from standard structural steel

members of sizes shown on the drawing.
8.
Insert plates will be provided at an interval of 600/750 mm

wherever cables are to be supported without the use of cable
trays, such as in trenches, while at all other places these will be at
an interval of 1250 mm.
260
Power Division
EARTHING SYSTEM
Earthing Conductors:
General:
All conductors buried in the earth and concrete shall be of mild steel. All
conductors above ground level and earthing leads shall be of galvanised
steel.
Constructional Features:
Galvanised Steel:
Steel conductors above ground level shall be galvanized according to IS:
2629.
The minimum weight of the zinc coating shall be 618 gm/sq.m. and the
minimum thickness shall be 85 microns.
The galvanised surfaces shall consist of a continuous and uniformly thick
coating of zinc, firmly adhering to the surfaces of steel. The finished
surface shall be clean and smooth and shall be free from defects like
discoloured patches, bare spots, unevenness of coating, smelter which is
loosely attached to the steel globules, spiky deposits, blistered surfaces,
flaking or peeling off etc. The presence of any of these defects noticed
on visual or microscopic inspection shall render the material liable to
rejection.
Galvanised steel shall be subject to four one-minute dips in copper
sulphate solution as per IS: 2633.
Materials for Earthmat for 400 kV SS Based on the Designs:
Main Earthing Conductor Buried in Earth
: 40 mm dia rod mild steel

(Main earth mat)
Conductor above ground and in concrete

& earthing leads (for equipment)
: 75 x 12 mm GS flat
261
Power Division
Electrodes
MS Rod
: 40mm dia, 3000 mm long
Riser below ground connecting

to above ground level GS flat for
Earthing
Earthing of Indoor LT panels and outdoor
Marshalling boxes, MOM Boxes, Junction
Boxes & Lighting panels
: 40mm dia MS Rod.
: 50 x 8 mm G.S. Flat
Earthing Leads
i) Columns and other auxiliary structures : 75 x 12 mm G.S. Flat
ii) Outdoor Cable trenches
Materials for Earthmat for 220/132 kV SS Based on the Designs:

Main Earthing Conductor Buried in Earth
: 75 8 mm mild steel flat

(Main earth mat)
Conductor above ground and in concrete

& earthing leads (for equipment)
Electrodes
MS Rod
: 50 x 8 mm GS flat
: 32 mm dia, 3000 mm long
Riser below ground connecting

to above ground level GS flat for
Earthing
Earthing of Indoor LT panels and outdoor
Marshalling boxes, MOM Boxes, Junction
Boxes & Lighting panels
: 50 x 8 mm MS Flat.
Earthing Leads:
i) Columns and other auxiliary structures : 50 x 8 mm G.S. Flat
ii) Outdoor Cable trenches
262
Power Division

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AC POWER SUPPLY SYSTEM

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SUBSTATION AUXILIARY A.C SUPPLIES INCLUDING