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11 KV Network

Manual
BU – DISTRIBUTION

Prepared by
Distribution Strategy & Planning

Document: Dist/11KV SOP/00/2014


Date: 1st Januray’14
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Standard Operating Procedure

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REVIEWED & APPROVED

DISTRIBUTION:
cc: CEO
cc: CDO Distribution
cc: DCDOs
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Table of Contents

REVIEWED & APPROVED ...............................................................................................................................................2

INTRODUCTION..................................................................................................................................................................14
SCOPE .............................................................................................................................................................................14
MAIN SECTIONS OF 11KV MANUAL ......................................................................................................................................14
APPLICABILITY ...................................................................................................................................................................14

SECTION A - 11 KV (NETWORK) OPERATION................................................................................................................ 15

OBJECTIVE ........................................................................................................................................................................16
SCOPE .............................................................................................................................................................................16
FUNCTIONS .......................................................................................................................................................................17
PROCEDURE FOR DECLARATION OF FAULTS IN 11-KV NETWORK .................................................................................................19
1. Main Cable Fault..............................................................................................................................................19
1.1 M.CF Fault Declaration Procedure ............................................................................................................................19
2. HT Linking Cable Faults ....................................................................................................................................20
2.1 HT Linking Cable Fault Declaration Procedure .........................................................................................20
3. HT Overhead Main Faults ................................................................................................................................21
3.1. HT Conductor Broken Single Phase Conductor Broken.............................................................................................21

CHAPTER 1 - ARRANGEMENT OF SHUTDOWN FOR LOCAL DISTRIBUTION TRANSFORMER IN 11KV GENERAL


DISTRIBUTION SUB-STATION (GD S/S) ........................................................................................................... 22

OBJECTIVE ........................................................................................................................................................................23
SCOPE .............................................................................................................................................................................23
TEAM FORMATION .............................................................................................................................................................23
LOGISTIC ..........................................................................................................................................................................23
TOOL BOX TALK .................................................................................................................................................................23
ROLES & RESPONSIBILITIES ..................................................................................................................................................23
PPES / SPES FOR FIELD STAFF ..............................................................................................................................................24
PROCEDURE: .....................................................................................................................................................................24
1. Arrangement of Shutdown for Local Transformer ...........................................................................................24
1.1. In case of Local Transformer 11KV Switch is Single Cable ........................................................................................24
1.2. In case of Local Transformer 11KV Switch is Double Cable to feeder Local Transformer and other HT circuits ......25

CHAPTER 2 - SHUTDOWN OF HT BUS-BAR OF A FEEDER SUB-STATION ....................................................................... 28

OBJECTIVE ........................................................................................................................................................................29
SCOPE .............................................................................................................................................................................29
TEAM FORMATION .............................................................................................................................................................29
LOGISTIC ..........................................................................................................................................................................29
RESPONSIBILITIES ...............................................................................................................................................................29
PPES / SPES FOR FIELD STAFF ..............................................................................................................................................29
PROCEDURE: .....................................................................................................................................................................30
1. Shutdown of HT Bus Bar of a feeder sub-station .............................................................................................30
1.1. Feeders OFF TFS with Danger Board .........................................................................................................................30
1.2. Position of 11KV Switch / Isolator / RMU in sub-station ..........................................................................................30
1.3. All linking cables incoming & outgoing from far end / S/S, RMU, Knife Switch & HT Overhead ...............................31
1.4. Position of 11KV switch of local transformer in sub-station where busbar is required dead ...................................31
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1.5. Performance Management (TATS) ...........................................................................................................................31


1.6. Shutdown of HT Busbar of a Non-Feeder Sub-Station Definition .............................................................................32

CHAPTER 3 - ARRANGEMENT FOR SHUTDOWN OF LT PANEL ...................................................................................... 35

OBJECTIVE ........................................................................................................................................................................36
SCOPE .............................................................................................................................................................................36
TEAM FORMATION .............................................................................................................................................................36
LOGISTIC ..........................................................................................................................................................................36
TOOL BOX TALK .................................................................................................................................................................36
PPES / SPES FOR FIELD STAFF..............................................................................................................................................37
PROCEDURE: .....................................................................................................................................................................37
1. In case of Local Transformer 11KV Switch is Single Cable ...............................................................................37
2. In case of Local Transformer 11KV Switch is Double Cable to feeder Local Transformer and other HT circuits
38

CHAPTER 4 - ARRANGEMENT OF SHUTDOWN ON HT OVERHEAD (O/H) ..................................................................... 40

OBJECTIVE ........................................................................................................................................................................41
SCOPE .............................................................................................................................................................................41
TEAM FORMATION .............................................................................................................................................................41
ROLES & RESPONSIBILITIES ..................................................................................................................................................41
PPES / SPES FOR FIELD STAFF ..............................................................................................................................................41
PROCEDURE ......................................................................................................................................................................42
PERFORMANCE MANAGEMENT (TATS) ..................................................................................................................................43

CHAPTER 5 - ARRANGEMENT OF SHUTDOWN FOR HT JUMPER / HT CABLE LEAD ....................................................... 44

OBJECTIVE ........................................................................................................................................................................45
SCOPE .............................................................................................................................................................................45
TEAM FORMATION .............................................................................................................................................................45
LOGISTIC: .........................................................................................................................................................................45
ROLES & RESPONSIBILITIES ..................................................................................................................................................45
PPES / SPES FOR FIELD STAFF ..............................................................................................................................................45
PROCEDURE ......................................................................................................................................................................46

CHAPTER 6 - DECLARATION OF PMT FAULT ................................................................................................................. 47

OBJECTIVE ........................................................................................................................................................................48
SCOPE .............................................................................................................................................................................48
TEAM FORMATION .............................................................................................................................................................48
LOGISTIC: .........................................................................................................................................................................48
ROLES & RESPONSIBILITIES ..................................................................................................................................................48
PPES / SPES FOR FIELD STAFF ..............................................................................................................................................48
RATING OF PMTS USED IN KESC NETWORK ...........................................................................................................................49
PROCEDURE OF DECLARATION OF PMT FAULT ........................................................................................................................49

CHAPTER 7 - TYPE TESTING OF SINGLE & THREE PHASE STATIC METERS ..................................................................... 51

PROCEDURE ......................................................................................................................................................................52
1. Selection Of Prototype Sample Meters ............................................................................................................52
2. Security & Meter Sealing .................................................................................................................................52
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3. Testing Schedule ..............................................................................................................................................52

CHAPTER 8 - EARTHING OF HT / LT EQUIPMENTS / MATERIAL .................................................................................... 54

KESC DISTRIBUTION NETWORK ................................................................................................................................... 54

INTRODUCTION..................................................................................................................................................................55
OBJECTIVE ........................................................................................................................................................................55
SCOPE .............................................................................................................................................................................55
APPLICATIONS: ..................................................................................................................................................................55
EARTHING / GROUNDING PROCEDURE: ..................................................................................................................................55
MEASUREMENT OF EARTH RESISTANCE: .................................................................................................................................56
RESPONSIBILITIES: ..............................................................................................................................................................57

CHAPTER 9 - SYSTEM IMPROVEMENT PROPOSAL FOR HT & LT DISTRIBUTION ........................................................... 58

PURPOSE:.........................................................................................................................................................................59
SCOPE .............................................................................................................................................................................59
DISTRIBUTION & RESPONSIBILITY ..........................................................................................................................................59
PREREQUISITES WITH THE PROPOSAL FOR APPROVAL .................................................................................................................59
COST BENEFIT RATIO: .........................................................................................................................................................61

CHAPTER 10 - SAFETY PRECAUTIONS FOR ISOLATION & MAINTENANCE WORK ON HT / LT POLE & OVER HEAD
LINES ............................................................................................................................................................. 62

OBJECTIVE ........................................................................................................................................................................63
SCOPE .............................................................................................................................................................................63
SAFETY TOOLS (PPES) / EQUIPMENTS FOR SUPERVISOR (ELECTRICAL) AND LINE MAN ...................................................................63
PPES AND TOOLS SHALL BE PROVIDED TO EVERY FIELD PERSON AS PER NATURE OF JOB. ....................................................................63
STANDARD TOOLS / EQUIPMENTS: ........................................................................................................................................64
SAFETY PROCEDURES AND PRECAUTIONS FOR WORKING ON POLES & TOWERS .............................................................................64
SAFETY PROCEDURE & PRECAUTIONS FOR WORKING ON OVERHEAD LINES ..................................................................................65
Working on Dead line and Equipment: .....................................................................................................................65
Working on lines and equipment adjacent to live equipment or lines: ....................................................................66
Work on Double Circuit Overhead lines with one Circuit alive shall not be carried out ............................................66
LT LEADS REPAIR/REPLACEMENT WORK FROM DISTRIBUTION TRANSFORMER TO LT BREAKER/DISTRIBUTION BOX. ..............................66
LT LEAD REPAIR/REPLACEMENT WORK FROM LT CIRCUIT BREAKER TO DISTRIBUTION BOX (DB) & DB TO LT O/H MAINS ....................67
REPLACEMENT OF FAULTY LT CIRCUIT BREAKER .......................................................................................................................68
REPLACEMENT OF LT FUSES IN DB ........................................................................................................................................68
REPLACEMENT OF LT FUSES IN SUB-STATION ..........................................................................................................................69
REPAIR OF LT MAINS JUMPERS..............................................................................................................................................70
REPAIR OF SERVICE CONNECTION JUMPER (LIVE LINE) ................................................................................................................70
INSTALLING OR REMOVING DOL METERS ...............................................................................................................................70
RESPONSIBILITIES OF SUPERVISOR(HT/LT): ............................................................................................................................71

CHAPTER 11 - RESTORATION OF 11-KV FEEDERS AFTER TRIPPING FROM GRID STATION ............................................ 72

INTRODUCTION: ............................................................................................................................................................73
SCOPE ............................................................................................................................................................................73
APPLICABILITY ...............................................................................................................................................................73
PROCEDURE ..................................................................................................................................................................73
1. Situation – 1.....................................................................................................................................................73
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2. Situation – 2.....................................................................................................................................................74
3. Situation – 3.....................................................................................................................................................74
3.1 SINGLE CABLE FEEDER AT GRID STATION. ................................................................................................................74
In case of single cable feeder from the G/S, If EFI at the incoming of the feeder is found Operated (or the incoming
OCB/VCB of the feeder is found operated) then it means that the main cable is sound, then ..............................................74
3.2 DOUBLE CABLE FEEDERS AT GRID STATION. .............................................................................................................75

CHAPTER 12 - LT SERVICE CABLE FAULT....................................................................................................................... 76

LT SERVICE CABLE FAULT(U/G) ............................................................................................................................................77


Consumer Residential (Individual) ............................................................................................................................77
LT SERVICE O/H (ABC/PVC) ..............................................................................................................................................77

HT BULK SUPPLY ......................................................................................................................................................... 79

INDUSTRIAL CONSUMER. ............................................................................................................................................ 79

Dismantling of Sub-Station .......................................................................................................................................79


GLOSSARY OF TERMS/ABBREVIATIONS .........................................................................................................................81
DEFINITIONS .....................................................................................................................................................................81

SECTION B – SSM ........................................................................................................................................................ 87

CHAPTER 1 - REPLACEMENT OF LT BREAKER, DB, LEADS OR DO CUTOUT .................................................................... 88

OBJECTIVE .....................................................................................................................................................................89
SCOPE: ...........................................................................................................................................................................89
ROLES & RESPONSIBILITIES: ..........................................................................................................................................89
1. SSM Site Supervisor: ........................................................................................................................................89
2. LT Supervisor: ..................................................................................................................................................89
3. AOC Supervisor: ...............................................................................................................................................89
4. SSM Sk. Fitter / S Sk. Fitter:..............................................................................................................................90
5. SSM Karkun:.....................................................................................................................................................90
6. AM – SSM & AE -SSM.......................................................................................................................................90
7. A.E /A.M /Manager--- SSM ..............................................................................................................................90
8. GM – HT: ..........................................................................................................................................................90
PERFORMANCE MANAGEMENT (TATS): ........................................................................................................................92
TOOLS, EQUIPMENT& LOGISTICS: .................................................................................................................................92
GANG FORMATION &COMPETENCY: ............................................................................................................................92
MATERIAL MANAGEMENT: ...........................................................................................................................................92

CHAPTER 2 - REPLACEMENT OF CT AND PT AND CLEANING OF CARBONIZED HT BUSBARS ......................................... 93

OBJECTIVE: ....................................................................................................................................................................94
SCOPE: ...........................................................................................................................................................................94
ROLES & RESPONSIBILITIES: ..........................................................................................................................................94
1. SSM Site Supervisor: ........................................................................................................................................94
2. AOC Supervisor: ...............................................................................................................................................94
3. SSM Sk. Fitter / S Sk. Fitter:..............................................................................................................................94
4. SSM Karkun:.....................................................................................................................................................95
5. AM – SSM & AE -SSM.......................................................................................................................................95
6. A.E /A.M /Manager--- SSM ..............................................................................................................................95
7. Manager – SSM: ..............................................................................................................................................95
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8. GM – HT: ..........................................................................................................................................................95
 GM – HT to oversight all above mentioned activities and fulfill requirement of tools, equipment, PPEs, SPEs
and logistics for field staff along with material management.PROCESS FLOWS / PROCEDURE: .............................95
PERFORMANCE MANAGEMENT (TATS): ........................................................................................................................96
TOOLS, EQUIPMENT& LOGISTICS: .................................................................................................................................97
GANG FORMATION &COMPETENCY: ............................................................................................................................97
MATERIAL MANAGEMENT: ...........................................................................................................................................97

CHAPTER 3 - REPLACEMENT OF RMU .......................................................................................................................... 98

OBJECTIVE: ....................................................................................................................................................................99
SCOPE: ...........................................................................................................................................................................99
ROLES & RESPONSIBILITIES: ..........................................................................................................................................99
1. SSM Site Supervisor: ........................................................................................................................................99
2. AOC Supervisor: ...............................................................................................................................................99
3. UGM Jointer Gang: ..........................................................................................................................................99
4. SSM Sk. Fitter / S Sk. Fitter:..............................................................................................................................99
5. SSM Karkun:.....................................................................................................................................................99
6. AM – SSM & AE -SSM ............................................................................................................................................99
7 A.E /A.M /Manager--- SSM ..................................................................................................................................100
8.GM – HT: ..............................................................................................................................................................100
PROCESS FLOWS / PROCEDURE:..................................................................................................................................100
PERFORMANCE MANAGEMENT (TATS): ......................................................................................................................100
TOOLS, EQUIPMENT & LOGISTICS: ..............................................................................................................................101
GANG FORMATION &COMPETENCY: ..........................................................................................................................101
MATERIAL MANAGEMENT: .........................................................................................................................................101

CHAPTER 4 - FORWARDING JOB TO SSM ................................................................................................................... 102

OBJECTIVE: ..................................................................................................................................................................103
ROLES & RESPONSIBILITIES: ........................................................................................................................................103
1. In-Charge 118: ...............................................................................................................................................103
2. Manager Network: ........................................................................................................................................103
3. Control Engineer: ...........................................................................................................................................103
4. DGM SSM:......................................................................................................................................................103
5. DGM Network: ...............................................................................................................................................103
6. Dispatch Supervisor: ......................................................................................................................................103
SSM CONTROL: ..............................................................................................................................................................103
HT OPN CONTROL: .........................................................................................................................................................103
1. HT AOC Supervisor: ........................................................................................................................................103
2. SSM Site Supervisor: ......................................................................................................................................104
3. GM – HT: ........................................................................................................................................................104
PROCESS FLOWS / PROCEDURE:..................................................................................................................................104
PERFORMANCE MANAGEMENT: .................................................................................................................................105

CHAPTER 5 - INSTALLATION OF 11KV SWITCHES AND ISOLATORS OR REPLACEMENT OF TROLLEY ........................... 106

OBJECTIVE: ..................................................................................................................................................................107
SCOPE: .........................................................................................................................................................................107
ROLES & RESPONSIBILITIES: ........................................................................................................................................107
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1. SSM Site Supervisor: ......................................................................................................................................107


2. AOC Supervisor: .............................................................................................................................................107
3. UGM Jointer Gang: ........................................................................................................................................107
4. SSM Sk. Fitter / S Sk. Fitter:............................................................................................................................107
5. SSM Karkun:...................................................................................................................................................108
6. AM – SSM & AE -SSM ..........................................................................................................................................108
8.A.E /A.M /Manager--- SSM ..................................................................................................................................108
9.GM – HT: ..............................................................................................................................................................108
PROCESS FLOWS / PROCEDURE:..................................................................................................................................109
PERFORMANCE MANAGEMENT: .................................................................................................................................109
TOOLS, EQUIPMENT& LOGISTICS: ...............................................................................................................................110
GANG FORMATION: ....................................................................................................................................................110
MATERIAL MANAGEMENT: .........................................................................................................................................110

CHAPTER 6 - REPLACEMENT OF LT LEADS OF TRANSFORMER TO LT PANEL, LT BUS BARS, HRC FUSES, BASES AND
OUTGOING LT CABLE TERMINATION IN SUBSTATION .................................................................................. 111

OBJECTIVE: ..................................................................................................................................................................112
SCOPE: .........................................................................................................................................................................112
ROLES & RESPONSIBILITIES: ........................................................................................................................................112
1. SSM Site Supervisor: ......................................................................................................................................112
2. AOC Supervisor: .............................................................................................................................................112
3. IBC Supervisor: ...............................................................................................................................................112
4. SSM Sk. Fitter / S Sk. Fitter:............................................................................................................................112
5. UGM Jointer Gang: ........................................................................................................................................113
6. SSM Karkun:...................................................................................................................................................113
7. AM – SSM & AE -SSM.....................................................................................................................................113
8. A.E /A.M /Manager--- SSM ............................................................................................................................113
9. GM – HT: ........................................................................................................................................................113
PROCESS FLOWS / PROCEDURE:..................................................................................................................................114
PERFORMANCE MANAGEMENT (TATS): ......................................................................................................................114
TOOLS, EQUIPMENT& LOGISTICS: ...............................................................................................................................115
GANG FORMATION &COMPETENCY: ..........................................................................................................................115
MATERIAL MANAGEMENT: .........................................................................................................................................115

CHAPTER 7- INSTALLATION OF NEW PMT ................................................................................................................. 116

OBJECTIVE: ..................................................................................................................................................................117
SCOPE: .........................................................................................................................................................................117
ROLES & RESPONSIBILITIES: ........................................................................................................................................117
1. SSM Site Supervisor: ......................................................................................................................................117
2. LT Supervisor: ................................................................................................................................................117
3. AOC Supervisor: .............................................................................................................................................117
4. SSM Sk. Fitter / S Sk. Fitter:............................................................................................................................117
5. SSM Karkun:...................................................................................................................................................118
6. AM – SSM & AE -SSM.....................................................................................................................................118
7. A.E /A.M /Manager--- SSM ............................................................................................................................118
8. GM – HT: ........................................................................................................................................................118
PROCESS FLOWS / PROCEDURE:..................................................................................................................................119
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PERFORMANCE MANAGEMENT: .................................................................................................................................119


TOOLS, EQUIPMENT& LOGISTICS: ...............................................................................................................................120
GANG FORMATION &COMPETENCY: ..........................................................................................................................120
MATERIAL MANAGEMENT: .........................................................................................................................................120

CHAPTER 8 - MASTER KEY HANDLING OF SUBSTATION ............................................................................................. 121

OBJECTIVE: ..................................................................................................................................................................122
SCOPE: .........................................................................................................................................................................122
ROLES & RESPONSIBILITIES: ........................................................................................................................................122
OPERATION SECTION: .......................................................................................................................................................122
SSM SECTION: ................................................................................................................................................................122
UGM SECTION: ..............................................................................................................................................................122
DISPATCH SUPERVISORS OF ALL 03 SECTIONS: .......................................................................................................................122
1. Gang supervisors: ..........................................................................................................................................122
2. Control In-Charge: .........................................................................................................................................123
3. Billing Managers / AMs: ................................................................................................................................123
4. DGM & GM: ...................................................................................................................................................123
5. Security Department:.....................................................................................................................................123

CHAPTER 9 - DIESEL GENERATORS............................................................................................................................. 124

OBJECTIVE: ..................................................................................................................................................................125
SCOPE: .........................................................................................................................................................................125
ROLES & RESPONSIBILITIES: ........................................................................................................................................125
1. Consumer: ......................................................................................................................................................125
2. DCDCO: ..........................................................................................................................................................125
3. GM – HT: ........................................................................................................................................................125
4. DGM – SSM: ...................................................................................................................................................125
5. Manager – SSM: ............................................................................................................................................125
6. GM – IBC: .......................................................................................................................................................125
7. DGM – Network: ............................................................................................................................................125
8. Manager Network: ........................................................................................................................................126
9. Generator Operator: ......................................................................................................................................126
10. IBC gang:....................................................................................................................................................126
ROUTINE MAINTENANCE: ...........................................................................................................................................126
PROCESS FLOWS / PROCEDURE:..................................................................................................................................127

CHAPTER 10 - REPLACEMENT OF TRANSFORMER ...................................................................................................... 128

OBJECTIVE: ..................................................................................................................................................................129
SCOPE: .........................................................................................................................................................................129
ROLES & RESPONSIBILITIES: ........................................................................................................................................129
1. SSM Site Supervisor: ......................................................................................................................................129
2. LT Supervisor: ................................................................................................................................................129
3. AOC Supervisor: .............................................................................................................................................129
4. SSM Sk. Fitter / S Sk. Fitter:............................................................................................................................129
5. SSM Karkun:...................................................................................................................................................129
6. AM – SSM & AE -SSM.....................................................................................................................................130
7. A.E /A.M /Manager--- SSM ............................................................................................................................130
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8. GM – HT: ........................................................................................................................................................130
PERFORMANCE MANAGEMENT (TATS): ......................................................................................................................131
TOOLS, EQUIPMENT& LOGISTICS: ...............................................................................................................................132
GANG FORMATION &COMPETENCY: ..........................................................................................................................133
MATERIAL MANAGEMENT: .........................................................................................................................................133

CHAPTER 11 .............................................................................................................................................................. 134

CONSTRUCTION OF NEW SUBSTATION ..................................................................................................................... 134

PURPOSE:.......................................................................................................................................................................135
SCOPE: ..........................................................................................................................................................................135
Material / Equipments: ...........................................................................................................................................136
Substation Location / Site Selection:.......................................................................................................................136
Construction Requirements: ...................................................................................................................................136
Provision of Fire Extinguisher..................................................................................................................................137
SUB-STATION CONSTRUCTION: ...........................................................................................................................................137
DOCUMENTATIONS (AGREEMENT /UNDERTAKING): ...............................................................................................................138

CHAPTER –12 RE-CONSTRUCTION OF NEW 11 KV SUB STATION ............................................................................. 139

OBJECTIVE: .....................................................................................................................................................................140
SCOPE: ..........................................................................................................................................................................140
ROLES & RESPONSIBILITIES ................................................................................................................................................140
PROCESS FLOW AND PROCEDURE ........................................................................................................................................141
Vacation of Substation............................................................................................................................................142
Execution of Civil Works ..........................................................................................................................................143
Reinstallation of Equipments and Accessories ........................................................................................................144
PERFORMANCE MANAGEMENT (TATS) ................................................................................................................................145
TOOLS AND EQUIPMENTS ..................................................................................................................................................145
TRAINING/ COMPETENCY ..................................................................................................................................................145
SAFETY...........................................................................................................................................................................145
Provision of Fire Extinguisher ..................................................................................................................................146
MATERIAL MANAGEMENT (ISSUANCE & RETURN OF MATERIAL) ................................................................................................146
ABBREVIATION ............................................................................................................................................................147
DEFINITION .....................................................................................................................................................................147

SECTION 3 - UNDERGROUND MAINTENANCE ............................................................................................................ 149

SCOPE: .........................................................................................................................................................................150
REQUIREMENT: ...........................................................................................................................................................150
FUNCTIONS .................................................................................................................................................................152
UGM SUB UNITS: ....................................................................................................................................................152
UGM CONTROL ROOM: ..........................................................................................................................................152
UGM TESTING UNIT: ...............................................................................................................................................152
UGM JOINTING UNIT: .............................................................................................................................................152
ROLES & RESPONSIBILITIES: GM INFRASTRUCTURE AND GM HT .......................................................................................153
UNDERGROUND MAINTENANCE – PROCESS FLOW ........................................................................................................157
HAZARD ASSOCIATED WITH CABLE JOINTING .............................................................................................................161
Implementation of SIP / NC Proposals ....................................................................................................................161
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PROPOSAL (Approved SIP SOP to be followed ) / SUB-ER / NEW SCHEMES PROCEDURE.......................................161


EXCAVATION OF TRENCH & LAYING OF UNDERGROUND CABLE ...........................................................................163
HAZARDS WITH CABLE LAYING ...............................................................................................................................164
MODE OF TRANSPORTATION AND LAYING OF CABLE ............................................................................................164
CLEARANCE OF WAY ...............................................................................................................................................164
JOINTING & TERMINATION OF CABLES...................................................................................................................164
HAZARD ASSOCIATED WITH PREPARATION OF CABLE JOINT / TERMINATION ......................................................164
Cable Joint Marker ..................................................................................................................................................165
Megger & Pressure Testing.....................................................................................................................................165
Cable Route sheet/drawing ....................................................................................................................................165
SAFETY PROCEDURES AND PRECAUTIONS FOR HT CABLE LAYING : ......................................................................165

RECOMMENDATIONS:............................................................................................................................................... 166

GENERAL SAFETY MEASURES..................................................................................................................................166


HT CABLE JOINTING. ...............................................................................................................................................166
Drawings .................................................................................................................................................................167
FORMS / DOCUMENTS:...........................................................................................................................................167
DEFINITIONS:...............................................................................................................................................................168
DEFINITION .....................................................................................................................................................................168

SECTION 4 - COMPOSITE GANG ................................................................................................................................. 170

INTRODUCTION: ..........................................................................................................................................................171
OBJECTIVE: ..................................................................................................................................................................171
WORKING PLAN: .........................................................................................................................................................171
WORK FLOW................................................................................................................................................................171
WORK SCOPE ...............................................................................................................................................................172
TRAINING ....................................................................................................................................................................172
GANG COMPOSITION: .................................................................................................................................................172
ROLES & RESPONSIBILITIES: ........................................................................................................................................172
1. 118 Response team: ......................................................................................................................................172
2. GM IBC ...........................................................................................................................................................173
3. Fitter ..............................................................................................................................................................173
4. L.M.O / Sk. / S.Sk. Lineman ............................................................................................................................173
5. Karkun ...........................................................................................................................................................173
6. DGM Networks ..............................................................................................................................................173
7. Maintenance Manager: .................................................................................................................................173
8. Dispatch supervisor: ......................................................................................................................................174
9. Site supervisor: ..............................................................................................................................................174
MATERIAL MANAGMENT: ...........................................................................................................................................174
PERFORMANCE MONITORING: ...................................................................................................................................174

SECTION 5 - UNIVERSAL GANG .................................................................................................................................. 175

INTRODUCTION: ..........................................................................................................................................................176
OBJECTIVE: ..................................................................................................................................................................176
WORKING PLAN: .........................................................................................................................................................176
WORK FLOW................................................................................................................................................................176
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WORK SCOPE ...............................................................................................................................................................177


TRAINING ....................................................................................................................................................................177
GANG COMPOSITION: .................................................................................................................................................177
ROLES & RESPONSIBILITIES: ........................................................................................................................................177
GM IBC ....................................................................................................................................................................178
DGM Networks .......................................................................................................................................................178
Maintenance Manager: ..........................................................................................................................................178
Dispatch supervisor: ...............................................................................................................................................178
Site supervisor:........................................................................................................................................................178
MATERIAL MANAGMENT: ...........................................................................................................................................178
PERFORMANCE MONITORING: ...................................................................................................................................178
SAFETY CONSIDERATIONS: ..........................................................................................................................................178

SECTION 6 - REGIONAL WORKSHOP .......................................................................................................................... 180

INTRODUCTION: ..........................................................................................................................................................181
OBJECTIVE: ..................................................................................................................................................................181
WORKING: ...................................................................................................................................................................181
WORK SCOPE ...............................................................................................................................................................181
WORK FLOW................................................................................................................................................................182
TRAINING ....................................................................................................................................................................182
ROLES & RESPONSIBILITIES: ........................................................................................................................................183
DGM- workshop: .....................................................................................................................................................183
Manager- workshop ...............................................................................................................................................183
AE/Supervisors- workshop ......................................................................................................................................183
All other staff- workshop: .......................................................................................................................................183
MATERIAL MANAGMENT: ...........................................................................................................................................183
SAFETY CONSIDERATIONS: ..........................................................................................................................................183

SECTION 7 – PREVENTIVE MAINTENANCE OF 11 KV FEEDERS .................................................................................... 184

PURPOSE OF PREVENTIVE MAINTENANCE: ............................................................................................................................185


OBJECTIVES: ...................................................................................................................................................................185
SCOPE: ..........................................................................................................................................................................185
ABBREVIATIONS: ..............................................................................................................................................................185
ROLES & RESPONSIBILITIES .........................................................................................................................................186
GM HT .....................................................................................................................................................................186
Manager Preventive Maintenance HT ....................................................................................................................186
Manager PM V/IBC .................................................................................................................................................186
Manager SSM .........................................................................................................................................................187
Manager UGM ........................................................................................................................................................187
SELECTION CRITERIA OF FEEDERS FOR PM:- ..........................................................................................................................187
PLANNING / SCHEDULING OF PREVENTIVE MAINTENANCE .......................................................................................................187
PROCESS DESCRIPTION & INTERFACES ..................................................................................................................................188
SCOPE OF WORK .............................................................................................................................................................189
IBC / VIBC ................................................................................................................................................................189
SSM/UGM ...............................................................................................................................................................189

1. PLANNING FOR MATERIAL FOR PM .................................................................................................................. 190


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2. PROCESS MONITORING .................................................................................................................................... 190

SECTION A – ANNEXURE ........................................................................................................................................... 191

ANNEX – ‘A’ - MATERIAL LIST ..........................................................................................................................................192


ANNEX – ‘B’ .................................................................................................................................................................193
ANNEX – ‘C’ .................................................................................................................................................................194
ANNEX – ‘D’ .................................................................................................................................................................195
ANNEX – ‘E’..................................................................................................................................................................196
ANNEX – ‘F’ ..................................................................................................................................................................197
ANNEX – ‘G’ .................................................................................................................................................................198
ANNEX – ‘H’ .................................................................................................................................................................199
ANNEX – ‘I’ ..................................................................................................................................................................200
ANNEX -‘J’ ....................................................................................................................................................................201
ANNEX -‘K’ ...................................................................................................................................................................202
ANN -‘L’ .......................................................................................................................................................................203
ANNEXURE-A ..................................................................................................................................................................204
ANNEXURE-B ..................................................................................................................................................................205
ANNEXURE-C ..................................................................................................................................................................206

SECTION B SSM ANNEXURES ..................................................................................................................................... 213

SECTION C ANNEXURE .............................................................................................................................................. 223

12.1 ANNEXURE “A” - FEEDER SURVEY CHECKLIST ......................................................................................................223


12.2 ANNEXURE “B” - MATERIAL REQUIREMENT LIST .....................................................................................................226
12.3 ANNEXURE “C” - FEEDER PREVENTIVE MAINTENANCE SCHEDULE ..............................................................................228
12.4 ANNEXURE “D” - SHUT DOWN REQUEST FORM ......................................................................................................229
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Introduction
11 KV Network Manual has been prepared to define work procedure for Operations, Substation
Maintenance and Underground maintenance in line with safety policies & Procedure. The Manual consist
of three major sections illustrating major functions of 11KV network i-e Operations, SSM & UGM.
The first section defines the work procedure of 11KV operations including rectification / isolation of faulty
equipment, arrangement of shutdowns for any addition / alteration in existing HT / LT network, preventive
/ corrective maintenance activities, addition of new schemes, system improvement proposals, proposal for
new 11 KV feeders, new HT linking cables, placement of new RMU, 11KV switches, Isolator, LT Panels and
protective devices.
Second section outlines the work procedure of Substation Maintenance including Installation or
replacement of transformer, 11KV switches, isolator, Replacement of trolley, CT PT, RMU, cleaning of
carbonization HT busbar etc. It also covers guidelines for construction of new substation and
Reconstruction of damaged substation including the responsibilities of all the concerned departments.

Third section covers Underground Maintenance section along with its major subsections involved in
underground cable maintenance, fault rectification and installation of new cable network. This Manual also
covers the concept of Composite gangs, Universal gangs and regional workshops along with clearly defined
roles and responsibilities of all the concerned.

Scope
This Manual covers routine operations, maintenance and system improvement on 11 KV Distribution
Network (UG / OH) all over KESC.

Main Sections of 11KV Manual


HT Operations
Substation Maintenance
Under Ground Maintenance
Composite Gang
Regional Workshop
Universal Gang
HT PM

Applicability
All KESC and 3rd Party staff.
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Section A - 11 KV (Network) Operation


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Objective
The basic objective of this policy is to stream line procedure to devise for implementation on 11KV
distribution network. Activities related to smooth and accident free function of HT / LT network
distribution. Rectification / isolation of faulty equipment, and to arrange back feeding to the effected
consumers, arrangement of shutdowns for any addition / alteration in existing HT / LT network, preventive
/ corrective maintenance activities, addition of new schemes, system improvement proposals, proposal for
new 11 KV feeders, new HT linking cables, placement of new RMU, 11KV switches, Isolator, LT Panels, 11 KV
knife switches, Installation of EFI, capacitor banks in all regions.

This SOP is intended for implementation across all 11 KV Network operations to establish accident free 11
KV switching operations for staff working on Live / Dead Networks.

Shift Engineer will act as key person for implementation of SOP for all switching activities on 11 KV network.

Scope
This Policy covers all 11 KV Distribution operation / Maintenance / System Improvement Proposals / New
Schemes activities in KESC HT / LT Distribution Network including:

 All Live Line operations of Existing 11 KV Networks


 Fault localization on HT Main / Linking cable and equipment e.g. PMTs / 11 KV switches, RMUs & knife
switches etc.
 Arrangement of shutdown for routine maintenance and shutdown for 11 KV distribution network
extension / expansions
 Shutdown of Power Trafo
 Switching ‘ON new 11 KV Feeder
 Switching ‘ON new 11 KV Linking cables
 Switching ‘ON new 11 KV PMT of different ratings
 Switching ‘ON new 11 KV S/S, RMUs , Knife Switches, EFI
 Switching ‘ON new extension on HT / LT circuits (Operation services required for shutdown and
energization of LT circuits)
 Switching ‘ON new LT Panels in SS and Circuit Breakers in Case of PMT.
 Switching ‘ON new LT Cables
 Preparation of scheme for new 11 KV feeder under System Improvement Proposals / Self Financing /
New Connection Purpose
 Preparation of scheme for new 11 KV Linking cables between Sub-Stations, RMU, HT O/H Mains
 Preparation of System Improvement Proposal for extension of HT over head Mains and New Linking
spans via HT O/H Mains.
 Recommendation for reinforcement of existing / installation of New Power Transformer at existing
Grids.
 Recommendation for installation of New 11 KV switches at existing Grids and Sub-Stations for
expansion of Network.
 Recommendation for development of new grid station as per requirement of load growth
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Functions
1. The 11 KV Network of each Region is to be monitored round the clock throughout 365 days by
respective shift Engineers (11 KV operation).

2. Shift engineers are responsible to take the charge from relieving shift with complete details of:
 HT Main cable faults
 HT linking cable faults
 LT cable faults (Excluding R-II where LT faults are being dealt by Concerned IBCs)
 HT O/H conductor broken and other O/H faults
 PMT & local Transformer fault
 11 KV switches / Isolator and RMU faults
 11 KV C.T /P.T faults
 L.T breaker Faults
 H.T Bus bar Carbonization Faults
 All leads jobs and the Transient / sub-transient faults
 Current status & number of feeders Tripping in hand with complete marking of operations (ON /
OFF)
 Position at the HT network Distribution Drawing & it must be updated timely to check the status of
network faults list (Annex-A)
 Feeders Priorities, Operation Standby, Generator Stand by.

3. All shutdown request & availing departments details must be listed along with relevant formalities i.e.
A, B and C forms (Annex-B).

4. Complete details of:


 HT Area Breakdown
 HT Jumper burnt out
 PMT link Blown off
 LT Panel/DB fuses Burnt out (Only in case of Shutdown for replacement/repair of fuses to put
local/PMT off in some cases is the responsibility of operation shift Engg/AOC AE)
 HT / LT cable leads / end damage details must be properly maintain for onward rectification in
receipt order except for any emergent nature of fault needs prompt attention.
 Timely Normalization after the clearance of fault / shut downs is the sole responsibility of shift
Engineer.

5. All operations must be performed keeping in view:


 Updated status of 11 KV network
 Day / evening peak load demand to avoid unnecessary interruption to the customers as well as to
maintain the loading well within the limit to restrict undesired addition of HT cable faults.
 Special attention is to be given to main cable faults & in case of area failure with no option for back
feeding, rotational area dumping with perfect time duration must be planned by Shift engineer
simply to provide the supply to all effected customers.
 All 11 KV feeders tripping and other faults details must be properly / timely maintained in the log /
fault / shutdown book. Any special instructions from the superior must be recorded in message
book.
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 Switching ‘ON’ HT equipments like PMT / Sub-Station, HT / LT cable etc must be followed as per
clearance given to GM / DGM / Manager / AM operation department from requesting / availing
department’s e.g. new connection, VIBC, IBC, HT / LT Network.

6. Addition of PMT, Sub-Station or any Other Equipment


All addition of equipments to the network e.g. knife switch, RMU, HT O/H mains, capacitor bank HT
/ LT cable etc. must be marked on network with complete details of its capacity, length, Sizes etc.

7. Feeder Tripping
 Shift engineer must clearly dictate all 11 KV operations leading to normalization / isolation of faulty
zone to AE / Supervisor / FM at concerned operation center, later will be responsible to perform all
operation as dictated by operation control (shift engineer). AE operation center / Supervisor / FM
are responsible to maintain their relevant network and marked all the operation on network
drawing & register all details in log book / fault book / Message book. All operations performed by
the operation center must be conveyed to shift engineer. ( Detailed SOP enclosed)
 SIP’s for HT / LT System Improvement Proposals for 11 V equipments / components new feeder
proposal are very important for smooth running of HT network. Proposal for new feeder may be
initiated if load on any 11 kv feeder reached to 70% or more, the proposal for additional feeder
must be considered as per system need. The basic observation for new Terminating Point of feeder
will be circulated from the Shift Engineer and field staff AE operation/AM/AM
(Admin)/Manager/DGM/GM/DCOO. The location of feeder Proposed must not be more than 5
kilometer and feeder proposed at load center to relive more feeders and provide operational
flexibility.
 Similarly new HT linking Cables, for interconnection of feeders and improves isolations of feeders to
Provide feeder to feeder back feeding options. The Proposed, switches RMU, Isolator must be clear
at where the new link required to be connected.
 Installation of Ring Main Units (RMUs) and Knife switches are very important the operational
concerned are required to Propose RMU at every long T-off of HT U/G / O/H network to
sectionalized the network in case of Tripping/faults. The installation of RMU/Knife switch will be
reduced the outage Time of the supply to customer.
 Installation of new PMT under System Improvement Proposal from GM LT/VIBC the providing of HT
feeder must be decided by operation as per loading Position of Power Transformer, feeder and load
on HT/LT network.
 Installation of Knife switches to be suggested at HT O/H Shackle points for large feeding HT O/H
feeders especially in the Orangi Town, vender, Uthal Bela the feeders of 100 or above HT spans.
This installation of Knife Switch will reduce the time for opened/closed the jumpers.
 In case of HT conductor Broken more then 2-Spans must be forward to the concerned GM
(Network) for repairing of HT Spans and normalizing the area.
 LT cable faults must be declared by operation with the coordination of the concerned
VIBC/Network and forward to UGM for repaired of cable special care must be taken during
repair/Back feeding of the area.
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Procedure for Declaration of Faults in 11-KV Network


1. Main Cable Fault
The HT 15 KV Cable of mostly 300mm2 size from Grid-Station to 1st Terminating N-KV
switch/Isolator/RMU/Knife switch or Directly Connected to the HT overhead Main is known as
“Main Cable”.

1.1 M.CF Fault Declaration Procedure

i. The first information of 11-KV feeder Tripping received from the concerned Grid station (S/D)
from the SBO to operation shift Engineer with the details of relays earth fault, Red, Yellow,
Blue, Instantaneous, with the details of surge (like light/heavy surge) observed at 11-KV VCB at
Grid-Station. Shift Engineer operation note all information at their log Book and desktop and
convey the same message to the concerned operation center and instruct to the AE/Supervisor
operation to dispatch MTL vehicle along with the line main gang.
ii. If all the relays at S/D operated then the shift engineer do not try the feeder, and field staff is
required to check the feeding of the 11-KV feeder and any information of flashover or blast on
HT/LT equipment received from the complaint center conveyed to HT operation must be check
first.
iii. If 11-KV feeder is terminating is Sub-Station VCB/OCB then the supervisor operation is required
to put OFF incoming S/D side switch of feeder in sub-station and try to check the different loops
of the 11-KV feeder and back feed at any other under load feeder with common isolations.
iv. In case of the all feeder loop found sound than the suspected Main cable fault can be declared
and conformed the Main cable fault if the main cable in back feeded at any other isolation
feeder’s feeding. If the isolation feeder tripped OFF then the main cable fault conform declared
with the remaining of back feeding operations.
v. After declaration of main cable fault the feeders 11-KV switch VCB at S/D must be at OFF,
trolley stage (TFS) rack out with Dander Board, the main cable fault also in the knowledge of
the Grid-Staff. (SBO)
vi. In Sub-Station the incoming S/D 11-KV switch trolley must be OFF trolley lower (T/L). If 11-KV
isolator than if must be OFF and Ground (E), In case of RMU incoming S/D side cable OFF and
Ground, Knife switch must be in OFF Position with loads opened and short at the knife switch,
similarly if the main cable is directly terminating at HT overhead mains cables lead must be
open and short by operational staff.
vii. After isolating the main cable from sub-station/RMU/Knife switch and S/D side with opened the
back plate of the S/D switch through concern SBO by GSM Gangs the job of main cable fault
forwarded to concerned underground maintenance department of R-I, II, III and IV etc.
viii. The area of the Effected main cable fault to be back feeded on the other feeders with common
isolations with the monitoring of loading position day/evening peak and must be in permissible
limit to avoid the addition of the cable faults.
ix. The operations carried out for the main cable fault of the feeder must be marked on shift
engineer network and concerned operation center network with details note in the log book.
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x. In case of overloading expected during the evening peak hours the concert plan for the load
management must be observed by the Manager/Admin/AM/Shift engineer. Due to over
loading of the feeders taken the load of main cable faults feeder the rotation wise area
dumping is also the last option to save the network for further fault.
xi. The priority of main cable fault must be decided by the shift engineer/Manger
(admin)/DGM/GM as per network condition to clear the fault by UGM.
xii. After the testing procedure for U/G cable fault location pin painting of the fault, the necessary
jointing/termination and end repairing of the main cable fault, and final testing of the fault the
clearance of the main cable fault should be forwarded to concerned operation shift engineer by
the UGM.
xiii. After receiving of the clearance of main cable fault the concerned operating shift engineer
required to normalized the area of feeders at its normal feeding and standard isolation with
reversed all the performed operation and remove the back feeding of all loops.

2. HT Linking Cable Faults


HT cable of 300 mm2 & 185 mm2 sizes are used in HT linking cables between Sub-Station inter
connection, RMU incoming/outgoing loops, PMT to PMT, O/H to O/H, and PMT to HT overheads
are used in KESC Distribution System all called linking cable (HT links).

2.1 HT Linking Cable Fault Declaration Procedure

i. Feeder Tripping information received from the concerned Grid (S/D) SBO to shift Engineer
Operation.
ii. After conformation of Main Cable fault is healthy by try the main cable at no load or back feed
at any other feeder. It’s the indication that fault occurred at the outgoing loops of the feeders
cable or other equipments like 11 KV switches, RMU, S/S bus bar, HT O/H Mains fault, PMT,
local Transformers of sub-station.
iii. At 1st Sub-Station / RMU / Knife switch / overhead where the feeder is terminated, all outgoing
11KV loops put ‘OFF’ with incoming S/D side put OFF.
iv. Main cable or feeder from the S/D put ON at no load.
v. Now the only 11KV Bus-Bar of the incoming Sub-Station put on if the feeder NOT Tripped OFF
than its means that the 11KV Bus-Bar is sound / Healthy all cable/Bus-Bar shrouds Trolley,
relays etc. are in sound position if intact properly.
vi. If the feeder consists 03 Nos outgoing loops than the isolation of other feeders must be clearly
marked and clear/conformed to the field staff AE/Supervisor operation of the connected area
operation center.
vii. Try the loops one by one by reducing the relay setting at the existing feeder say two loops
found normal and the energized then the third loop do not try.
viii. Check the complete feeding of third loop if it’s the mixture of HT O/H Mains cables, Sub-Station
RMU, Knife switch etc. Then sectionalized the loop into two or more sections.
ix. If no any visible fault found than section/part of the loop one by one try if tripping occurred at
any section then, the fault, of HT linking cable must be declared clearly.
x. If fault between tow Sub-Stations occurred then the both sides of cable isolate at both the sub-
stations with OFF if switch trolley lower (T/L), if isolator/RMU then OFF and ground (OFF,E), if
O/H then open the leads at both end, if load at O/H and PMT.
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xi. Job of the linking cable fault with the position of cable at the both end note in operation shift
engineer and area operation center, same fault forwarded to the Under Ground Maintenance
department (UGM) for repair purpose.
xii. The remaining area of the feeder may be back feed at any other isolation feeder with the
position of network decided by the shift engineer operation and field operation carried out by
AE/Supervisor operation of the area.
xiii. All operation must by mark at network with loading of relevant feeders. w.r.t day and evening
peak, proper schedule and load sheet must be maintain by shift engineer (OPN) and area
operation center

3. HT Overhead Main Faults


3.1. HT Conductor Broken Single Phase Conductor Broken
i. In case of HT conductor broken the feeder will be Tripped OFF with the short circuit phase (R, Y
& B) relays or E/F instantaneous relays at S/D and same information. Conveyed by the SBO S/D
to operation shift engineer
ii. The operation shift engineer conveys the message to area operation center regarding feeder
tripping. The operation coordinates with LT/Complaint Network and if any message regarding
the flashover report and wire broken received from the complaint department.
iii. The operation center dispatched MTL with line Main gang Head by AE/Supervisor operation
and put incoming OFF is S/S, RMU or Knife Switch.
iv. Check the HT overhead Mains, with all phases (R, Y &B) conductor and double earth (D/E) wire,
all shackle points. If the visible wire broken of X-Span found and burning of HT Jumpers than
operation supervisor informed to the shift engineer for details of faults.
 Nos. of phase conductor broken (span)
 HT Jumpers burnt out report with pole No.
 D/E wires in X-No of span broken from pole # X-Pole No Y.
 HT insulator/Disc, Pin insulator damaged/cracked at pole No. X
 HT Bracket damaged.
 Position of HT Poles (damaged, bend, dash etc)

v. The effected loop completely isolate by the operation staff and line off and short /Earth at both
the effected ends.
vi. The area which can be back feed at any other feeder the operations performed by operation
supervisor with the isolation/loading position of feeder as per direction of shift engineer carried
out.
vii. The complete details of HT overhead fault if the no of Spans broken in 02 Spans should be
repaired by operation with the help of IBC while more than 02 spans to be conveyed to
network for its repairing with details of number of S/S or PMTs effected
viii. After arrangement of proper shut down for repaired of HT O/H mains Spans by Operation. . The
effected portion handover the Mains (Network Department) staff and the HT conductor
repaired/Replaced by the same.
ix. After complete the task by Mains the clearance given to the operation shift engineer with the
details of short and other necessary information, same convey by operation shift engineer to
area operation for normalization of the fault with removal of back feeding.
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Chapter 1 - Arrangement of Shutdown for Local


Distribution Transformer in 11KV General Distribution
Sub-Station (GD S/S)
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Objective
To assure arrangement of shutdown on Local Transformer of 11KV Distribution Sub-station for replacement
of local transformer, reinforcement of trafo or repair / replace / reinforcement of HT/LT cables feed to
trafo, replacement of LT panel / LT breaker or provide additional circuit to local trafo with all safety policies
and 11KV operational procedures

Scope
This SOP shall apply to all 11KV Operation Regional KESC and 3rd Party employees working on 11KV AOC and
11KV operation control rooms working on arrangement of shutdown for 11KV busbar of sub-station

Team Formation
Concerned AOC operation gang with following team formation:

 01 Supervisory officer: AE / Sub-Engineer / Supervisor / Electrician General


 01 Line Man: (S. SK L/M, L/M)
 02 Karkun / Helper:

Logistic
 MTL

Tool Box Talk


 AM / AE operation will make ensure for tool box talk in area operation centre before leaving the AOC
for arrangement of local transformer
 Discuss the hazard and its mitigation procedures
 Discuss special event of shutdown for local transformer of S/S with complete details and proper steps

Roles & Responsibilities


Manager / AM operation and control room shift engineers are responsible to arrange shutdown for local
transformer in particular S/S Shift engineer will communicate all relevant 11KV / LT operations through
shutdown forms and wireless communication to AE / Sub-engineer AOC

i. All operations must be clearly mention in separate sheet and C-Form duly signed by shift engineer
ii. AOC AE / Sub-engineer is responsible to carried out all the operations as directed by shift engineer
operation
iii. AOC AE / Sub-engineer responsible to completely de-energized the HT/LT feed of local transformer,
properly isolate and short all the outgoing LT circuits from LT panel
iv. AOC AE is responsible to handover the shutdown from to requesting / availing department
v. AOC AE is responsible to normalize shutdown of local transformer after completion of work and
getting clearance from requesting / availing department in writing with the instruction / clearance of
operation shift engineer
vi. AOC AE is responsible to check the all lines / circuit grounding / earth position and remove before
energization of circuits
vii. In case of any LT Circuit is required to back feed to provide supply to circuit then it should be clearly
mention and cable leads at O/H or any terminating point from S/S to be isolate properly by AE / Sub-
Engineer operation with the coordination of IBC / VIBC and LT Network
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PPEs / SPEs for field staff


Before starting any work at site, personnel protective equipments & special tools shall be checked
comprehensively by concerned department staff. Some tools normal used are listed below:

i. Uniform
ii. Safety shoes
iii. Helmet with chin strip
iv. Rubber & leather gloves
v. Live line tester
vi. Full body harness with front position belt
vii. Earth / grounding rope
viii. Danger board, safety tape
ix. Emergency light
x. Rain coats & gum boots (depending upon weather)

Procedure:
1. Arrangement of Shutdown for Local Transformer
 The name of sub-station with its feeder name must be clearly communicate by shift engineer
operation to AOC AE at which the local transformer shutdown is requested
 The 11KV switch for local transformer in relevant sub-station must be clearly identified by AE /
Sub-Engineer AOC with its HT feed whether its single cable or double cable

1.1. In case of Local Transformer 11KV Switch is Single Cable


 Put 11 KV local transformer OCB OFF and T/L requesting S/S
 Put 11KV local transformer if VCB OFF and TFS trolley first stage requesting S/S
 Get all the LT bulk supplies or service cables isolated from the consumer end (with
intimation to consumer)
 Pull out all the HRC fuses at LT panel (8-way or 4-way)
 Check HT/LT supply from live line tester
 Short all the phases and neutral to earth at LT panel with the earthing rope
 If any LT overhead or U/G circuit is back feed by VIBC / IBC or LT network with the
coordination of AOC AE, then the LT cable from panel & O/H properly isolate and
danger board place at that circuit
 Having danger board at 11KV switch of local transformer and LT panel after
arrangement of shutdown
 AE / Sub-Engineer operation give the clearance and B-Form to AE / Sub-Engineer
requesting / availing department to start work
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11KV Busbar in S/S

OFF T/L TFS


(WDB)

HT Cable
95 mm2
11KV Local
Incoming Transformer HT
Outgoing
11KV Feeder Circuit
Isolation
11 / .4 KV Local Transformer (500,
750, 1000, 1250 & 1500 KVA)
Single Core

HT Cable
300 mm2
Lead

Put LT
Breaker OFF LT Breaker .4 KV LT 8-Way
Panel

Pull out the HRC


Fuses at LT Panel LT Circuit to
Multi Story
LT O/H Circuit Building

If LT Circuit O/H
back feed from
IBC / VIBC LT Circuit to
Leads of cable must
LT Bulk
be open & short
Supply

1.2. In case of Local Transformer 11KV Switch is Double Cable to feeder Local Transformer and
other HT circuits

 Due to non-availability of switch in 11KV sub-station sometimes local transformers


11KV OCB / VCB are made double cable with outside PMTs, O/H mains or other
outgoing circuit to S/S, RMU etc.
 In such case special care is required from HT side when arrangement shutdown of local
transformer
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11KV Busbar in S/S

OFF T/L Case-A

Opposite
S/S PMTs

LT
Breaker

Case-C Case-B

Local
OFF T/L Transformer OFF T/L
Switch
11KV S/S
HT O/H Mains

OFF T/L Leads opened Local


(TFS) WDB & short Transformer

In above mentioned drawing if local transformer 11KV switch is double cable with o/H HT circuit then the
HT/LT from the other cable must be isolate properly
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Case-A

If local transformers 11KV switch is double cable local transformer outside S/S PMT then:

Option 1: switch OFF trolley lower (T/L) or trolley first stage (TFS) and at outside PMT HT cable leads
required to be open and short
Option 2: Local transformer cable can be isolate from switch & connect second cable (S/S .PMT & OH side)
to switch.

Tagging of both HT Cable at local switch must be mentioned; however, the option to open HT cable lead
from PMT is safer from back feeding point of view.

Case-B

If local transformers switch is double case local transformer HT O/H outgoing outside S/S then switch of
local transformer OFF trolley lower (T/L) for and OFF trolley first stage (TFS) for VCB with danger board
(DB). Isolate the HT cable from O/H by proper shutdown and open the leads of HT cable terminate from
sub-station to O/H with properly short & ground

Case-C

If local transformers switch is double cable local transfer HT outgoing cable to sub-station then switch of
local transformer OFF trolley lower (T/L) for OCB & OFF trolley first stage (TFS) for VCB with danger board
(DB). Isolate the HT cable from the far end sub-station put switch of local S/S side OFF T/L or TFS and back
feed the area if network loading of other feeders permitted
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Chapter 2 - Shutdown of HT Bus-bar of a Feeder Sub-


Station
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Objective
To assure arrangement of shutdown on 11KV Busbar of Distribution Sub-station with all safety polices and
11KV operational procedures

Scope
This SOP shall apply to all 11KV Operation Regional KESC and 3rd Party employees working on 11KV AOC and
11KV operation control rooms working on arrangement of shutdown for 11KV busbar of sub-station

Team Formation
 01 Supervisory officer: AE / Sub-Engineer / Supervisor / Electrician General
 01 Line Man: (S. SK L/M, L/M)
 02 Karkun / Helper:

Logistic
 MTL / Truck with B/L

Responsibilities
Manager / AM operation and control room shift engineers are responsible to arrange 11KV busbar
shutdown. Shift engineer will communicate all relevant 11KV operations through shutdown form and
wireless communication to AE / Sub-engineer area operation centre

i. All operations must be clearly mention in separate sheet and C-Form duly signed by shift engineer
ii. AOC AE / Sub-engineer is responsible to carried out all the operations as directed by shift engineer
iii. AOC AE / Sub-engineer responsible to completely de-energize the HT cables all incoming / outgoing
circuits and LT supply from local transformer with proper checking & grounding of circuits
iv. AOC AE is responsible to handover the shutdown from to requesting / availing department
v. AOC AE is responsible to normalize shutdown after getting clearance from requesting/availing
department with the instruction / clearance of operation shift engineer

PPEs / SPEs for field staff


Before starting any work at site, personnel protective equipments & special tools shall be checked
comprehensively by concerned department staff. Some tools normal used are listed below:
i. Uniform
ii. Safety shoes
iii. Helmet with chin strip
iv. Rubber & leather gloves
v. Live line tester
vi. Full body harness with front position belt
vii. Earth / grounding rope
viii. Danger board, safety tape
ix. Emergency light
x. Rain coats & gum boots (depending upon weather)
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Procedure:
1. Shutdown of HT Bus Bar of a feeder sub-station
1.1. Feeders OFF TFS with Danger Board
Get the feeder _(Name of feeder)_from relevant grid station OFF trolley first stage (TFS) and with
danger board (WDB) by operation engineer from concerned S/D SBO

1.2. Position of 11KV Switch / Isolator / RMU in sub-station


In the sub-station where the feeder is directly terminating the AE of AOC put incoming grid station
side Switch / Isolator / RMU / Knife Switch as under:
 If 11KV OCB (Oil Circuit Breaker) installed in S/S then identify the incoming S/D side switch
and put OFF trolley lower (T/L)
 If 11KV VCB (Vacuum Circuit Breaker) installed in S/S then identify the incoming S/D side
switch and put OFF trolley first stage (TFS)
 If 11KV insulator in S/S then identify the incoming S/D side insulator and put OFF and ground
(E)
 If 11KV feeder is directly terminating at RMU (Ring Main Unit) then identified the incoming
S/D side and put OFF incoming side & ground (E)
 If 11KV feeder is directly terminating at Knife Switch then put OFF the Knife Switch and check
the contact of Knife Switch and properly short & ground
 If 11KV feeder is directly terminating at sub-station # 1 where the main cable is double with
the cable that directly terminate at S/S # 2, then ensure that in S/S # 1 S/D OFF T/L (WDB) then
put incoming of S/S # 1 & S/D side OFF T/L (WDB)

OFF TFS WDB


11 KV Feeder
Terminating in HT Cable lead opened, short & ground
S/S Switch OFF T/L S/D 11 KV
(WDB) Panel
HT Pole OFF TFS WDB

OFF E
11 KV Feeder (WDB)
Terminating in OFF TFS WDB
RMU

OFF E
11 KV Feeder (WDB) OFF TFS WDB
Terminating at
Isolator
OFF &
Contact
11 KV Feeder
Ground
Terminating in Knife
Switch
K/S
OFF TFS WDB
11KV Feeder first
terminating at non-
feeding S/S then
directly to main S/S DFF T/L
(WDB)

Ensure OFF T/L


(WDB)
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1.3. All linking cables incoming & outgoing from far end / S/S, RMU, Knife Switch & HT
Overhead
All the HT (higher tension) linking cables terminating in the sub-station must be isolated and dead
firstly from where the same are in energized position and then in this sub-station.

From far end sub-station, RMU, Knife Switch on HT overhead Mains


 All far end S/S incoming or outgoing OCB (oil circuit breaker) OFF trolley lower
 At for end S/S incoming or outgoing isolator OFF and ground (E) and ensure put OFF source
supply first then ground the isolator
 All far end RMU incoming or outgoing in RMU put OFF and ground
 At far end knife switches incoming or outgoing in knife switch OFF and short / ground on cable
side in case of HT O/H
 HT cable incoming & outgoing leads opened, short and earthed in case cable feed through
PMT & HT O/H lines
 HT cable incoming & outgoing leads opened short and earthed in case of cable feed through
HT overhead

In sub-station where busbar is required dead


After isolation of all incoming and outgoing HT cables isolated from far end, all incoming and
outgoing 11KV VCB, OCB, Isolator put OFF trolley lower (T/L), OFF trolley first stage (TFS) and OFF &
ground in case of isolator

Bulk Supply 11KV Switch


If there are bulk suppliers from the sub-station, get them isolated from HT/LT side at consumer end
then in the KESC sub-station, following position should be put in bulk supply switch
 B/S 11KV Switch OFF trolley lower (TL), if it is OCB
 B/S 11KV Switch OFF trolley first staged (TFS), if it is VCB
 Ensure 11KV switch at B/S consumer side OFF T/L or TFS by consumer intimation

1.4. Position of 11KV switch of local transformer in sub-station where busbar is required dead
 11KV OCB / VCB of the local transformer OFF trolley lower / trolley first staged respectively
 Put OFF LT breaker of local transformer
 Pull out all the HRC fuses at the LT panel
 Short all the phases and neutral to earth at LT panel with the earthing rope
 Hang the danger boards flags / all the 11KV switch at far end sub-station, RMU & Knife Switch
 Handover the shutdown B form to requesting / availing department by operation (AOC)

1.5. Performance Management (TATS)


TATS for shutdown of 11KV busbar of substation = 1 to 1.3 hours. Performance of shift engineer &
AOC centre based on the work load at 11KV operation network faults / tripping and nos of
shutdowns in the AOC. Give the clearance to shutdown requesting / availing department
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RMU
S/S-C
OFF
E
OFF TL or TFS

Leads open & short


OFF & Isolated OFF TL
contact with proper 11KV Sub-
grounding Station-A
A
K/S 30 MVA
B
HT O/H Mains OFF T/L TFS Grid Station
HT Main Cable
C

E 132 / 11KV
OFF OFF
&E T/L
S/S-B Incoming S/D
side switch OFF Feeder C OFF
T/L, TFS, OFF TFS WDB at S/
& Earth Isolator D

OFF TL HT B/S
or TFS Consumer Local
(WDB) Transformer

TL LT CB
LT
Panel

Pull LT
Fuse

1.6. Shutdown of HT Busbar of a Non-Feeder Sub-Station Definition

Non-Feeder Sub-Station:
In 11KV distribution network a sub-station is called non-feeder sub-station where HT main cable
(feeder) from grid station is not directly terminate and symbolical represent as O, whereas in feeder
sub-station main cable is directly terminate in sub-station is called feeder sub-station symbolical
represent as

Identification of feeder name at which sub-station is energize when 11KV busbar shutdown of non-
feeder sub-station is required the OCB shift engineer first check the feeding point of that particular
busbar with feeder name and its isolation points
At far end sub-station, RMU, O/H mains, knife switch where the S/S in energize put incoming (source
point) as under:

 At far end sub-station OFF trolley lower (T/L) with danger board (WDB) if it is OCB (oil circuit
breaker
 At far end sub-station OFF trolley first stage (TFS) with danger board (WDB) if it is VCB vacuum
circuit breaker
 At far end sub-station OFF trolley earth if it is isolator (put OFF source supply first also WDB)
 At far end ring main unit (RMU) OFF and earth (put OFF source supply first) WDB
 At far end knife switch OFF remove contact & short them
 At far end HT O/H main then operation HT cable leads & short them (arrange shutdown of
overhead first)
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HT O/H RMU

OFF E O/H
(WDB)

HT Cable
leads open
& short

OFF & E
(WDB) OFF TL or 11KV Feeder
OFF T/L TFS (WDB)

OFF with open


OFF T/L contacts & short
OFF T/L

Grid
Station

11KV non-feeder K/S


sub-station for Local
shutdown of HT Transformer
33
11KV busbar 33
LT Circuit
Breaker
OFF RMU

LT
Panel

Pull LT
Fuse

Rest of operation as above explained in feeder sub-station 11KV busbar shutdown (clause #
9.1A(c)
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OCR shift engineer operation instruct SBO grid for put


OFF TFS of Name of feeder & S/D

Concerned S/D SBO put OFF TFS of feeder and in


form to OCR

Shift engineer operation OCR convey message to AE


AOC for feeder OFF TFS

AOC AE will put incoming S/D side in S/S 11KV switch


isolator or RMU OFF T/L, TFS & E

OCR shift engineer operation convey message for put


OFF T/L, TFS, E, contact ______, leads operation at
far end cable from S/S, RMU, K/S & HT O/H

AOC AE operation after perform operation at far end


S/S, RMU, K/S, O/H informed to OCR shift engineer

OCR shift engineer operation convey message to put


all switch in S/S, OFF T/L. TFS, E, including local
transformer with OFF ACB and fuses pulled out from
LT panel circuits

AOC AE performed operation for required S/S as


directed by shift engineer operation i.e. put all switch
isolators RMU OFF T/L,TFS, E, including switch of
local transformer in S/S with put OFF ACB (LT
Breaker) with pulled out the fuses at LT panel

At existing S/S if B/S of HT switch is available then this


switch will be OFF TL/TFS and also OFF & TL at HT
consumer end also

Open back plate of last OCB / VCB &check the supply


with live line teste if supply found absent then make
proper earth of 11KV busbar

AOC AE must inform the total position of operation to


shift engineer then handover the busbar to
requesting / availing department of shutdown

END
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Chapter 3 - Arrangement for Shutdown of LT Panel


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Objective
To assure arrangement of shutdown on LT (.4KV) 8-way & 4-way panel feed through local transformer of
11KV General Distribution Sub-station

Scope
This SOP shall apply to all 11KV Operation Regional KESC and 3rd Party employees working on 11KV area
operation centre ( AOC) and 11KV operation control rooms working on arrangement of shutdown for .4KV
LT Panel

Team Formation
Concerned AOC operation gang with following team formation:
 01 Supervisory officer: AE / Sub-Engineer / Supervisor / Electrician General
 01 Line Man: (S. SK L/M, L/M)
 02 Karkun / Helper:

Logistic
 MTL / Truck with B/L

Tool Box Talk


Manager / AM operation and control room shift engineer operations are responsible to arrange shutdown
of LT panel. Shift engineer operation will communicate all relevant HT / LT (11KV /.4 KV) operation through
shutdown form and wireless communication to AE / Sub-Engineer operation centre:

i. All operation must be clearly mention in separate sheet and C-Form duly signed by shift engineer. In
case of forced / emergency shutdown AE / Sub-Engineer must be follow the wireless communication
instruction of shift engineer operation and follow all the steps of operation as directed by shift engineer
ii. AOC AE / Sub-Engineer is responsible to carried out all the operation as directed by shift engineer
operation
iii. AOC AE / Sub-Engineer is responsible to completely de-energize the local transformer HT supply if
desired in shutdown, put LT breaker of local transformer OFF (if available LT breaker) check the supply
of HT by live line tester & LT by tester or test lamp and pullout the LT fuses from the LT panel circuits
with proper checking and grounding of the LT panel & LT circuits
iv. AOC AE is responsible to handover the shutdown form to requesting / availing department
v. AOC / AE is responsible to normalize shutdown after getting written clearance from requesting /
availing department with the instruction / clearance of operation shift engineer
vi. AOC AE is responsible to check the all circuit & LT panel grounding position and remove all shorts and
ground before normalization of shutdown
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PPEs / SPEs for Field Staff


Before starting any work at site, personnel protective equipments & special tools shall be checked
comprehensively by concerned department staff. Some tools normal used are listed below:

i. Uniform
i. Safety shoes
ii. Helmet with chin strip
iii. Rubber & leather gloves
iv. Live line tester
v. Full body harness with front position belt
vi. Earth / grounding rope
vii. LT tester or test lamp
viii. LT fuse puller
ix. Rain coats & gum boots (depending upon weather)

Procedure:
If only LT panel shutdown is required check the following position by AE AOC:

i. Is local transformer HT cable is connect as single cable with 11KV OCB or VCB?
ii. Is local transformer HT cable is connected as double cable with 11KV OCB or VCB for local
transformer or outside PMT, S/S, O/H live etc?
iii. Is LT circuit breaker installed at local transformer?
iv. Is at LT panel HRC fuses (base & grips) are available?

1. In case of Local Transformer 11KV Switch is Single Cable


 Put 11 KV local transformer OCB OFF and T/L with danger board (WDB) for the S/S where LT panel
shutdown is required
 Put 11KV local transformer if VCB OFF and TFS trolley first stage (OFF TFS) with danger board (WDB)
for the sub-station where LT panel shutdown is required
 Put LT breaker OFF (if available) and check the supply at LT breaker
 Pull out all the HRC fuses at LT panel (8-way or 4-way)
 Check HT/LT supply from HT/LT live line tester
 If any LT overhead or U/G circuit is back feed by VIBC / IBC or LT network with the coordination of
AOC AE, then the LT cable from panel & O/H properly isolate and danger board place at that circuit
 All LT busbars (R, Y B & Neutral) of LT panel must be properly short with earth rope and ground
with earth terminal
 Having danger board at 11KV switch of local transformer and LT panel after arrangement of
shutdown of LT panel
 AE / Sub-Engineer operation give the clearance and B-Form to AE / Sub-Engineer requesting /
availing department to start work
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11KV Busbar in S/S

OFF T/L TFS


(WDB)

HT Cable
95 mm2
11KV Local
Incoming Transformer HT
Outgoing
11KV Feeder Circuit
Isolation
11 / .4 KV Local Transformer (500,
750, 1000, 1250 & 1500 KVA)
Single Core

HT Cable
300 mm2
Lead

Put LT
Breaker OFF LT Breaker .4 KV LT 8-Way
Panel

Pull out the HRC


Fuses at LT Panel LT Circuit to
Multi Story
LT O/H Circuit Building

If LT Circuit O/H
back feed from
IBC / VIBC LT Circuit to
Leads of cable must
LT Bulk
be open & short
Supply

2. In case of Local Transformer 11KV Switch is Double Cable to feeder Local Transformer
and other HT circuits

Due to non-availability of switch in 11KV sub-station sometimes local transformers 11KV OCB / VCB
are made double cable with outside PMTs, O/H mains or other outgoing circuit to S/S, RMU etc.

In such case special care is required from HT side when arrangement shutdown of local
transformer
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11KV Busbar in S/S

OFF T/L Case-A

Opposite
S/S PMTs

LT
Breaker

Case-C Case-B

Local
OFF T/L Transformer OFF T/L
Switch
11KV S/S
HT O/H Mains

OFF T/L Leads opened Local


(TFS) WDB & short Transformer

In above mentioned drawing if local transformer 11KV switch is double cable with o/H HT circuit then the
HT/LT from the other cable must be isolate properly

Case-A
If local transformers 11KV switch is double cable local transformer outside S/S PMT then switch OFF trolley
lower (T/L) or trolley first stage (TFS) and at outside PMT HT cable leads required to be open and short

Case-B
If local transformers switch is double case local transformer HT O/H outgoing outside S/S then switch of
local transformer OFF trolley lower (T/L) for and OFF trolley first stage (TFS) for VCB with danger board
(DB). Isolate the HT cable from O/H by proper shutdown and open the leads of HT cable terminate from
sub-station to O/H with properly short & ground

Case-C
If local transformers switch is double cable local transfer HT outgoing cable to sub-station then switch of
local transformer OFF trolley lower (T/L) for OCB & OFF trolley first stage (TFS) for VCB with danger board
(DB). Isolate the HT cable from the far end sub-station put switch of local S/S side OFF T/L or TFS and back
feed the area if network loading of other feeders permitted
At all above cases after shutdown of HT feed to local transformer the rest of operations for LT panel to be
performed as per above procedure
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Chapter 4 - Arrangement of Shutdown on HT Overhead


(O/H)
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Objective
To assure arrangement of shutdown on HT / 11KV overhead mains with all safety policies and 11KV
operational procedures

Scope
This SOP shall apply to all KESC 11KV operation region and 3rd party employees working on 11KV AOC and
11KV operation control rooms working on arrangement of shutdown for HT overhead mains

Team Formation

 Supervisory Officer: At least A.E / L.M.O, /Supervisor / Sub-Engr. / Electrician general


 Line man: At least S.SK.L/M, L/M
 Karkun/helper: At least K.K.

Logistic:

 MTL / Truck with B/L

Roles & Responsibilities

 Manager / AM operation and control room shift engineers are responsible to arrange 11KV HT
overhead shutdown in case of HT wire broken, HT jumpers burnout, new HT O/H spans pulling, D/E
wire broken, addition / alteration of HT jumper / HT cable leads shutdown of other equipment like PMT
etc where HT O/H is involved. Shift engineer will communicate all relevant 11KV operations through
shutdown form and wireless communication to AE / Sub-Engineer area operation centre (AOC)

a. All operations must be clearly mentioned in separate sheet and C-form duly signed by shift engineer
b. AOC AE / Sub-Engineer is responsible to carried out all the operations as directed by shift engineer
c. AOC AE / Sub-Engineer responsible to completely de-energize all HT feeding at incoming / outgoing
and T-OFF HT circuits and LT circuits / street light phase with the coordination of IBC / VIBC with
proper testing / checking of HT / LT supply whereas the HT line short and ground will be provide by
AOC lineman as per instruction of AE / Sub-Engineer operation
d. Proper danger board / sign and red flag must be put where the HT O/H is under shutdown
e. AOC AE is responsible to handover the shutdown form to requesting / availing department
f. AOC AE is responsible to normalize shutdown after getting written clearance from requesting /
availing department with the instruction / clearance of operation shift engineer

PPEs / SPEs for field staff


 Before starting any work at site, personnel protective equipments & special tools shall be checked
comprehensively by concerned department staff. Some tools normal used are listed below:

i. Uniform
ii. Safety shoes
iii. Helmet with chin strip
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iv. Rubber & leather gloves


v. Live line tester
vi. Full body harness with front position belt
vii. Earth / grounding rope
viii. Danger board, safety tape
ix. Emergency light
x. Rain coats & gum boots (depending upon weather)
xi. Safety belt & harness
xii. Goggals
xiii. Safety belt and full body harness
xiv. L/M toolbox kit

Procedure
a) Tool box talk in Case of HT Wire Broken

HT wire broken 3-span


b/w PMT-1 & PMT-2

P-1 6-Span 5-Span 5-Span P-12

PMT-1
PMT-3 PMT-2

Shackle Pin RMU

S/S-3

S/S-4 S/S-2
PMT-4
Feeder-III

S/D

S/S-1 Feeder-I

PMT-5
S/S-5

Feeder-II

S/D

 Let HT wire broken in 3-span from PMT # 1 to PMT # 2 and 11KV feeder # I tripped OFF
 AOC AE / Sub-Engineer check the HT O/H mains of the feeder-I and check physical position of HT wire
broken
 In sub-station-3 put OFF trolley lower (OFF TL) if OCB is installed of pole # 1 to isolate the HT O/H
feeding of the feeder-I
 AOC AE / Sub-Engineer must check the isolation of feeder-II in RMU where conform that in RMU O/H
pole 12 side is OFF position
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 AOC AE / Sub-Engineer instruct to lineman operation to open the HT jumper near the PMT-2 towards
PMT-1 side & short them after isolating LT O/H Mains & Street/ Public Light by IBC/VIBC.
 Similarly open the jumper at PMT # 1 towards the RMU side shackle point of PMT # 1 T-OFF and short /
ground the HT O/H mains
 Put earth and short on all the three phases of 11KV O/H mains on both sides of wire broken
 Pull out HRC fuses from DBs of all the PMTs (PMT # 1 & 2) in the position of wire broken
 All LT circuits in a position under shutdown of wire broken mains should be isolated and made dead
from feeding ends and also provide a short on it
 Public light phases in a portion under shutdown should be isolated / dead and short & ground
 Back feed the affected area by AOC where possible & feeders load permits the back feeding
 Give clearance to mains maintenance for repair of wire

Performance Management (TATs)


TAT for HT overhead shutdown = 01 Hour
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Chapter 5 - Arrangement of Shutdown for HT Jumper / HT


Cable Lead
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Objective
To assure arrangement of shutdown for repair / open / close HT jumpers or cable leads in case of fault, area
back feed operation, isolation portion of HT network from HT overhead or HT cable with all safety polices
and 11KV operational procedure

Scope

This SOP shall apply to all KESC 11KV operation region and 3rd party employees working on 11KV AOC and
11KV operation control rooms working on arrangement of shutdown for HT jumper / HT cable leads

Team Formation

 Supervisory Officer: At least A.E / L.M.O, /Supervisor / Sub-Engr. / Electrician general


Line man: At least S.SK.L/M, L/M
 Karkun /helper: At least K.K.

Logistic:

 MTL / Truck with B/L

Roles & Responsibilities

Manager / AM operation and control room shift engineers are responsible to arrange HT jumper / HT cable
leads shutdown in case of HT wire broken, HT jumpers burnout , new HT O/H spans pulling, D/E wire
broken, addition / alteration of HT jumper / HT cable leads shutdown of other equipment like PMT etc
where HT O/H is involved. Shift engineer will communicate all relevant 11KV operations through shutdown
form and wireless communication to AE / Sub-Engineer area operation centre (AOC).

a. All operations must be clearly mentioned in separate sheet and C-form duly signed by shift engineer
b. AOC AE / Sub-Engineer is responsible to carried out all the operations as directed by shift engineer
c. AOC AE / Sub-Engineer responsible to completely de-energize all HT feeding at incoming / outgoing and
T-OFF HT circuits and LT circuits / street light phase with the coordination of IBC / VIBC with proper
testing / checking of HT / LT supply whereas the HT line short and ground will be provide by AOC
lineman as per instruction of AE / Sub-Engineer operation
d. Proper danger board / sign and red flag must be put where the HT O/H is under shutdown
e. AOC AE is responsible to handover the shutdown form to requesting / availing department
f. AOC AE is responsible to normalize shutdown after getting written clearance from requesting / availing
department with the instruction / clearance of operation shift engineer

PPEs / SPEs for field staff

Before starting any work at site, personnel protective equipments & special tools shall be checked
comprehensively by concerned department staff. Some tools normal used are listed below:
i. Uniform
ii. Safety shoes
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iii. Helmet with chin strip


iv. Rubber & leather gloves
v. Live line tester
vi. Full body harness with front position belt
vii. Earth / grounding rope
viii. Danger board, safety tape
ix. Emergency light
x. Rain coats & gum boots (depending upon weather)
xi. Safety belt & harness
xii. Goggals
xiii. Safety belt and full body harness
xiv. L/M toolbox kit

Procedure

 If a HT jumper or HT cable lead is to be repaired / opened / closed in cable of HT jumper burnout or


open HT jumper for shutdown / isolate of circuit. Purpose or close HT jumper to connect the HT O/H
mains with isolating portion or network, similarly HT cable lead repair / open and close, the same
should be isolate from the source of supply means put OFF the HT feed to made dead (from all linking
circuits at the both for ends like:

i. OFF trolley lower if it is OCB in sub-station


ii. OFF trolley first staged if its VCB in sub-station
iii. OFF and earth if it is isolator. (Put OFF source supply first in S/S)
iv. OFF and earth if it is RMU (put OFF source supply first)
v. HT cable leads opened, short and earth in case of PMT
vi. HT cable leads opened short and earth in case of overhead line
vii. Knife switch OFF and short / ground on cable side or jumper side in case of PMT or O/H (proper
opening of contacts be seen before short / ground)

 Check the HT circuit with live line tester and confirmed the absence of HT feed
 Put short / ground on all the three phases of 11KV O/H mains and cables on all linking supply sides at
on span before the working point within visual range by lineman
 HT jumper and HT cable lead near PMT, HT links from DO Cutout for all three phases must be isolate /
drop and short / earth

 All LT circuits terminating at the working point should be isolated and made dead from feeding ends
and also provide a short on it by earth rope
 Public light (street light) phase terminating at working point should be isolated and dead from both
sides
 AOC AE / Sub-Engineer give clearance to lineman L/M operation to start work for HT jumper / HT cable
lead repair / open / close job

Performance Management (TATs)

TAT for HT jumper / HT cable lead repair = 30 minutes


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Chapter 6 - Declaration of PMT Fault


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Objective
To assure arrangement of declaration of pole mounted transformer(PMT) fault in 11KV distribution
network with all safety polices and 11KV operational procedures

Scope
This SOP shall apply to all KESC 11KV operation region and 3rd party employees working on 11KV AOC and
11KV operation control rooms working on arrangement for declaration of PMT fault

Team Formation
 Supervisory Officer: (At least A.E / L.M.O, /Supervisor / Sub-Engr. / Electrician general)
 Line man: (At least S.SK.L/M, L/M)
 Karkun/helper: (At least K.K.)

Logistic:

 MTL / Truck with B/L

Roles & Responsibilities


Manager / AM operation and control room shift engineers are responsible for declaration of PMT fault in
case of PMT is faulty due to any reason at 11KV distribution network. Shift engineer operation will
communicate all relevant 11KV operations through wireless communication to AE / Sub-Engineer area
operation centre

a. All operations must be clearly communicate by shift engineer and AOC AE / Sub-Engineer is
responsible to perform all operation as per instruction of operation engineer
b. AOC AE / Sub-Engineer is responsible to declare fault of PMT and isolate the PMT whereas L/M
operation will be responsible to provide short / earth where necessary as per instruction of AE
operation

PPEs / SPEs for field staff


Before starting any work at site, personnel protective equipments & special tools shall be checked
comprehensively by concerned department staff. Some tools normal used are listed below:

i. Uniform
ii. Safety shoes
iii. Helmet with chin strip
iv. Rubber & leather gloves
v. Live line tester
vi. Full body harness with front position belt
vii. Earth / grounding rope
viii. Danger board, safety tape
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ix. Emergency light


x. Rain coats & gum boots (depending upon weather)
xi. Safety belt & harness
xii. Goggals
xiii. Safety belt and full body harness
xiv. Megger
xv. L/M toolbox kit

Rating of PMTs used in KESC Network


a) 10 KVA
b) 15 KVA
c) 25 KVA
d) 50 KVA
e) 100 KVA
f) 150 KVA
g) 200 KVA
h) 250 KVA
i) 400 KVA
j) 500 KVA
k) 630 KVA in kiosk

Procedure of Declaration of PMT Fault


11KV Feeder Tripped OFF due to PMT Fault
a) 11KV operation central room shift engineer inform through wireless to AOC AE /Sub-Engineer
regarding the tripping of feeder and instruct him to check the feeder and put OFF all incoming &
outgoing switches / isolator in S/S
b) AOC AE / Sub-Engineer will put OFF all incoming and outgoing switches / isolation of sub-station where
the main cable of the feeder is directly terminated
c) As per SOP of the feeder try the shift engineer operation will try only main cable of the feeder by put
ON feeder from grid station. If feeder ON then instruct the AOC to check the outgoing loops
thoroughly
d) If in outgoing loop one PMT is found all HT link fuses (R, Y & B) blown OFF then inform to shift
engineer regarding the HT fuses link blown OFF
Shift engineer operation instruct AOC for trying PMT from HT side at no load and before try of PMT
check PMT as follow
Check List before PMT Trying
a) Conform / check the HT feeding point of PMT from lower (T/L) in case of OCB, OFF trolley first stage in
case of VCB and OFF and ground in case of isolator
b) In case of RMU put portion / circuit of PMT OFF and ground
c) In case of knife switch put OFF knife switch and check the contact is properly opened
d) AOC AE / LM of operation will check the supply from 11KV live line tester at the PMT where link found
blown OFF
e) Put LT breaker of PMT OFF
f) Pull all the LT fuses of PMT DBs
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g) Proper physical check of HT wire spans at that portion of 11KV network where PMT link found blown
OFF
h) Proper physical check of LT O/H & circuit of PMT at which HT link blown OFF. If wire broken is found
then inform to IBC / VIBC LT network for LT wire broken
i) If any visible fault other than PMT links blown OFF not found then PMT may be try at no load
j) PMT HT busbar to be check
k) Busbar to DO cutout HT jumper to be check
l) DO Cutout to be check along with supporting pin insulator
m) DO Cutout to HT bushing cambric lead to be check
n) PMT HT & LT bushing to be check
o) PMT oil position, silica gel and oil leakage to be check
p) Check the temperature of PMT
q) PMT cooling pipes conservator tank to be check for oil leakage observation
r) Transformer bushing to LT breaker leads to be check
s) Transformer breaker to outgoing leads towards check meter and DBs to be check
t) If any abnormality found by AOC then inform to operation shift engineer
u) If all above items found normal then try PMT at no load with thin wire at HT fuse links with the
conformation of LT breaker is in OFF position and all LT fuses in all circuit DBs are putout

Declaration of PMT Fault

a) If PMT try on no load and HT links (fuses) of red, yellow & blue any one or two or all three phases links
(R, Y & B) are blown OFF then PMT is declared faulty
b) If voltage is not found at LT bushing or LT breaker incoming then declared PMT faulty with the remarks
LT winding is open circuit
c) If unbalance voltage found at LT side then forward to SSM for proper checking with help of IBC testing
gang and tape changer position to be check
d) If oil leakage observed from HT / LT bushing, tank, cooling pipes, valves etc then forward PMT to SSM
for checking of PMT

PMT Faulty is Declared By

a) PMT is declared faulty by operation department the shift engineer in coordination with AOC
supervisor declares the fault.

PMT Faulty Job is Forwarded By

a) After declaring PMT as a faulty and isolating it from HT and LT side, the job is forwarded to SSM
Department in control room of SSM to in charge supervisor.

Source of Job Forwarding

a) The job is forwarded through wireless on cell phone or through email.

Performance Management (TATs)


TAT for HT overhead shutdown = 01 Hour
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Chapter 7 - Type Testing Of Single & Three Phase Static


Meters
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Procedure
Guide line for type testing of single & three phase static meters.

1. Selection Of Prototype Sample Meters


Minimum three (03) Nos. sample of proto type meters have to be selected for type testing by the
manufacture.

The prototype meters will be approved prior to dispatching for type testing by the technical
scrutiny committee in line with recommendation given in the technical evaluation report.

2. Security & Meter Sealing


 Selected meters for type testing should be sealed with signing by the KESC inspection team
(indelible ink marker) at all sites i.e. rear, front and both sides. Also meters will be sealed by
KESC security slips on both sides of the meter.

 Prior to the start of type tests, KESC inspection team should thoroughly verify their signature
and after that physical inspection of the offered sample meters testing would be carried
out.

 If any ambiguity is found in the signature or any discrepancy during the physical inspection of
the sample meters, decision for rejection of sample are at the sole discretion of KESC inspecting
officials.

3. Testing Schedule
 Prior to the departure of KESC witnessing officials, the bidder should furnish the test sequence
/ schedule duly signed from laboratory officials for all type tests.

 The Tests Schedule would clearly mentioned the list of type tests to be carried out with
sequence in which these tests shall be performed on the offered prototype sample meters
in compliance with relevant IEC and KESC specification.

 KESC inspecting officials should check the calibration of all tests equipment before
proceeding to type tests.

 For single phase meters Clause 7.2 & 7.2.1 & for three phase static meters Clause 7.2
(Security Features), as mentioned in KESC Specification are to be carried out in
Independent Laboratory of international repute.

 Verification test for functionality of software as per clause 13.4 of KESC Specification for
three phases static meters are to be carried out at Independent laboratory of
international repute.

 If any tests mentioned in 2.3.3 & 2.3.4 cannot be conducted at the designated laboratory,
the KESC officials can take the decision to conduct these tests at manufacturer’s work, if
facilities for these tests are available.
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 Test Protocol for each test shall be signed by KESC Inspectors and bidder before start of
each test.

4. Signature Verification (On prototype sample for type test)

 The KESC Inspection team should verify their signatures on the meters at any time during
the type testing.

 Out of the two meters selected for type testing, if any one meter fails in one test, then the
bidder shall offer another sample for type testing, all tests (previously carried out and
remaining test shall be carried out on the new offered sample meter, if again the new
offered proto type meter (sample) fails in any test, then type testing shall be ceased and
meters shall be declared rejected being failed in type testing.

 The meters under tests would be sealed daily by the KESC officials at the close of testing
activity on that day.

 Every day prior to the start of testing, KESC officials would check for the healthiness of
sealing.

 KESC inspecting officials may ask for any test / tests other than specified in relevant IEC /
KESC specification to confirm the features already mentioned in KESC specification.
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Chapter 8 - Earthing Of HT / LT Equipments / Material

KESC Distribution Network


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Introduction
The non current carrying metallic parts in every electrical installation are connected to the underground
earthing system for safety of personnel and for discharging fault currents. The connecting of non-current
carrying metallic parts to underground earthing system are called equipment earthing (grounding).

An electrical earthing system is designed to provide safe & correct operation of the network under normal,
earth fault & transient conditions.

Objective
To provide guide lines for proper earthing / grounding of HT / LT equipments / materials used in KESC
distribution network.

Scope
This SOP covers the requirement of grounding system and need to develop for a systematic approach to its
design, installation, inspection, testing and maintenance of distribution grounding system.

A good earthing system is required for:

 Safety against shocks to persons & maintenance staff


 To ensure correct & timely operation of protective equipments
 Correct operation of electricity supply network & to ensure good power quality.
 Protection of buildings & installation against lightning

Applications:
 Each & every Sub-Station equipment, PMT, RMU, DO cut out, Lightning arrestors, Capacitor banks,
Knife Switches & all metallic enclosures for protective equipment, distribution & metering
equipments shall be earthed / grounded as per Annexure – C,D,E&F (Attached)
 Every Fifth pole of HT / LT network shall be earthed as per Annexure – B, G,H & I (Attached)
 Earth wire shall be provided for LT O/H Mains as per Annexure – G&H (Attached)
 Guard wire to be provided at both sides of the pole between neutral and earth for LT O/H mains as
per Annexure G & H (Attached)
 Guard wire shall be provided on HT & LT at each Railway and Road crossings.
 Double Earth wire on HT O/H Mains shall be provided as per Annex’ I (Attached)’
 The messenger of HT / LT Aerial Bundled Cable shall be connected to the KESC earthing system at
both ends.

Earthing / Grounding Procedure:


 BOM for single earthing system - as per Annexure – A (Attached)
 Take a piece of 3/0 stranded HDBC conductor of length calculated from proposed grounding pit bore
depth to pole base / grounding strip in S/S
 Punch 70 mm² tinned copper lug with crimping tool at one end of 3/0 stranded HDBC conductor
 Bend lug at palm side from centre so that the hole on lug should align to the hole on earth plate
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 Fix lug on earth plate with brass nut & bolt (as shown in sketch) of size mentioned in BOQ
 Punch 70 mm² tinned copper lug on the other end of stranded 3/0 copper conductor for connection
at PMT pole base / earthing strip in S/S
 Bore up to a depth of at least 21 feet with a circular diameter of 5 inch
 Insert stranded copper conductor 3/0 with copper plate in the bore upto its depth from plate side
 Insert ¾ inch PVC pipe in the bore up to the depth for afterward curing & maintenance of earth point
as per Annexure – B (Attached).
 Take out one terminal of stranded copper 3/0 conductor and connect it with the pole at base with 70
mm² copper lug.
 Fill the bore with a mixture of lime, salt & coal in the ratio of 1:2:3 respectively 18" (inches) below the
ground level. Fill 12 “concrete in the bore & finally back fill the bore with normal soil up to ground
level
 Excavate trench of 6 inches width and 12 inches deep from grounding point (bore) to pole base &
from pole to pole / S/S wall. PVC pipe will also run with conductor in trench & will be terminated
slightly above pole base
 Place stranded copper grounding conductor emanating from grounding pit in the trench up to pole
base & connect copper lug at pole base & at mid point with nut & bolt already welded / on earth strip
in S/S
 Tee-off trench & conductor with PG clamp in run for 2nd pole for grounding of PMT. Back filling of
trench & connection of conductor with 70 mm² lug at pole base.
 Fill trench with concrete up to 9 inches from the base & back fill the trench up to ground level with
normal soil
 Connect ground terminals of all equipment i.e. PMT neutral, D.O. cutout, capacitor, DB, knife switch
etc & at 11 KV OCB / VCB panel , LT panel, Transformer, EFI etc in S/S

Measurement of Earth Resistance:


 Ground resistance is to be checked at pole base & at mid point on pole (at earthing strip in S/S) as
detailed below
 Connect the equipment as shown in Annexure ‘J’ (Attached) Use test leads with a cross sectional area
of at least 2.5mm.
 Locate the current probe ‘C’ at 50m away from the grounding pit under test. Ideally try and place the
current probe at right angles to the footpath to avoid any buried ground conductors, metallic water
pipes, metal fences, etc. Where access is restricted, ‘C’ may be placed at 20m from grounding pit.
 Ensure all electrodes are in an approximate straight line and buried to a depth of 300 mm to
500 mm. It is very important that the current probe is driven deep enough into the soil to ensure a
low resistance connection to ground.
 Take resistance readings with the potential probe ‘P’ at 50%, 60% and 70% of the distance to current
probe ‘C’ (i-e. at 25 m, 30 m and 35 m for ‘C’ at 50 m).
 There should be no more than 10% difference between the three (3) readings. If there is, then
reposition the current electrode ‘C’ at 100 m as the resistance area of the earthing system must be
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quite large and is interfering with the measurement. Repeat the resistance measurements with the
potential probe ‘P’ at 50%, 60% and 70% of the distance to ‘C’.

Responsibilities:
 Detailed survey is to be conducted by the designated field staff, assigned by respective regional
DCOO’s / DD / GMs (HT / LT), which will point out the locations / equipments where grounding is to
be provided.
 DGM /Manager / AM will maintain data base / record of grounding pits in their respective regions /
IBC / VIBC / HT / LT.
 Designated field staff under the supervision / guidance of AM in their respective regions / IBC / VIBC /
HT / LT shall test the resistance of existing earthing points. The resistance should be 1 or less
than 1 Ω. If the resistance exceeds 1Ω, complete maintenance of earth point is to be carried out
with watering to limit the ground resistance to the defined limit.
 The disconnected earth conductor in run from earthing point for PMT & Sub Station is to be repaired
in accordance to the sketch attached Annexure - K & L (Attached).
 Each earthing point shall be checked & tested once in a year.
 System engineering department (SE) is to provide NEW earthing for PMTs & Sub Stations only.
 GM (SE) will arrange contractor / man power / field staff for providing new earthing point as per
requirement of GM IBC / VIBC & GM HT / LT.
 Grounding / Earthing done by the contractor shall be tested by the SE engineers in the presence of
contractor and forwarded a test report to GM HT / LT of respective region.
 GM SE will ensure proper connection of PMT neutral, D.O base, capacitor, metallic enclosures etc
with earth point after arranging shut down & likewise all earthing terminals should be looped &
connected to earth point in Sub Stations.
 GM (SE) shall update the progress to concerned DCOO’s / Dir (TPRE)) / GM (HT / LT) on monthly basis.
 New Connection (NC) department shall ensure all extensions in HT / LT network distribution system is
properly earthed / grounded as per this SOP & details of all earthing points along with the earth
resistance result shall be submitted to GM HT / LT of respective region prior to switching ‘ON’ the
scheme.
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Chapter 9 - System Improvement Proposal for HT & LT


Distribution
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Purpose:
The basic objective of this policy is to stream line procedure to device and implement system improvement
proposal (SIP) related to new / Reinforcement of PMT / Distribution Transformer in S/S, HT & LT cables / HT
& LT O/H Mains, or any other associated addition / modification to the HT and LT Network.

Scope
The policy covers all system improvement proposals / activities in KESC- HT / LT Distribution network.

Distribution & Responsibility


 This procedure applies to all four Distribution Regions (R-I, R-II, R-III, R-IV) of KESC.
 GM -LT and GM - HT are responsible for technical vetting of the proposal and DCOO for the final
approval subject to fulfillment of entire pre-requisite mentioned in this policy.
 DGM / Manager / GM – IBC / LT and GM - HT Network may initiate the proposal for system
improvement as per the requirement of the area. GM - IBC will ensure the prerequisites to be
completed as mentioned in section 4 below and attached with the proposal before submitting for
approval.
 The proposal is to be checked at DCOO office for budgetary allocation regarding provision of the
scheme.
 There should be a budgetary allocation for System Improvement Proposals (SIPs) as a part of the
annual budget. The certificate from the Region mentioning the total budget and all the available
should be provided by the GM (Finance) of the DCOO’s office this will result in prioritizing the
sensitivity of schemes. (Format Attached Annexure-G)
 After approval of SIP scheme, it would be executed as proposed.

Prerequisites with the proposal for approval


The proposal will only be approved by the DCOO, if it fulfills the following prerequisites:
 Cover sheet: Providing a synopsis of the case explaining why there is a need for the scheme. (Format
Attached as Annexure-A)
 Comments Sheet: For comments / remarks of all the concerned officials having signing and approval
authority. (Format Attached as Annexure-B)
 Certificate: To the effect that the scheme will not cater any new area development / commercial
building, any single commercial and industrial consumer.(Format Attached as Annexure-C)
 Separate sketches for Existing and Proposed system depicting a clear picture of the area, including all
the adjacent PMTs with ratings, LT / HT overhead / underground lines with lengths & conductor type
etc.
 Each drawing must be provided with SIP reference number and signatures of the concerned AE /AM
/Manager / DGM & GM – LT / HT
 (Format Attached as Annexure-D1 & D2 for Existing & Proposed system)
 Data sheet showing details of losses for all the PMTs adjacent to the proposed PMT location,
overloaded PMT. It must include: Losses incurred
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 Total Arrears and Recovery against billing


 Number of Legal / Illegal Consumers, In case of illegal connections, immediately disconnect
those connections and take action as per procedure.
 Loadings of PMTs in Amperes,
 Network managers are responsible to get the log register maintained for summer peak loading
of PMT & LT feeding network drawings. (Format attached Annex – E)
 In case any industry exist at the over loaded PMT, the details should be clearly mentioned as per the
format. (Format attached Annex-F)
 SIP for PMT / Sub -Station Transformer should be initialed if the PMT or S/S Transformer reached
above 70 % loading.
 The name of Grid station, Power Transformer (with capacity, summer day & evening peak loading ) &
11 KV feeder (with summer day & evening peal loading), sub-station & PMTs to be reflected on the
drawing.
 Maximum loading of sub-station local transformer / Pole Mounted Transformers (PMTs), their
capacity and all LT circuit loading.
 Size of existing and proposed HT & LT Cables / conductors
 PMT / Sub-Station local Transformer, HT and LT circuits proposed are to be highlighted.
 Span length of both, HT and LT circuits proposed to be indicated along with rating of proposed
Distribution Transformer on drawing.
 Percentage loading category wise on overloaded PMT (Residential /Com / Indus / Agr)
 Average percentage loss & No. of hook / illegal connection on overloaded PMT’s.
 SIP forwarded to R&D for technical revision should have commendation from GM VIBC/IBC.
 Addition / alteration in HT network should firstly be vetted from HT operation.
 In proposed system, PMT shall ne installed at the load center rather by the side of existing PMT or
reinforcement of existing one.
 The capacity of proposed pole Mounted Transformer (PMT) should be up to 250 KVA and each
scheme should have proposal of only one additional PMT or (reinforcement of PMT from 250 KVA to
500 KVA duly approved as a special case).
 Cost for proper earthing should be included on all newly proposed PMTs / Distribution Transformer in
S/S & HT / LT network.
 The LT circuit length of overhead Mains from PMT would be restricted to 12-spans. The length of one
span should not be more than 150 feet.
 GM (LT) / GM (HT) / GM (Finance) would ensure that all schemes / proposals stands approved before
December 31st enabling to complete execution up to 31st March of current financial year.
 Approved SIP schemes ready for execution should be mentioned in Annex. ‘F’.
 SIP scheme already approved for the adjoining area of current SIP should also be mentioned.
 BOM: (Bill of Material with updated rates of material)
 Manager Net Work will ensure the quantity requested commensurate with the work to be carried
out.
 For better commercial evaluation the BOM should be prepared very carefully costing at latest rates
should be based on of material.
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 Separate BOM / costing should be prepared for


 PMT / Sub-Station and allied material
 HT / LT cable with accessories
 HT / LT over head material
 Individual and final consolidated material and cost would be included in the SIP.
 In case of dismantling of any material / equipment, it is mandatory to specify the quantity of material
to be credited at KESC store or use on corrective head with the approval of DCDO/CDO. It must
contain SIP reference with signatures of the concerned officials.
 Preferably, refurbished PMTs will be installed in such proposals.

Cost Benefit ratio:


The investment to be done must be mentioned with benefit to cost ratio and pay back period.
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Chapter 10 - Safety Precautions for Isolation &


Maintenance Work On HT / LT Pole & Over Head Lines
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Objective
To assure safe work place and environment for maintenance, operation at KESC HT / LT over head
distribution network. Promote and facilitate continuous improvement of electrical safety policies and
practices.

Scope
This SOP shall apply to all KESC employees working on HT / LT poles and lines, visitors, on-site
contractors, subcontractors and any other related person, to prevent electrical and related hazards.

Safety Tools (PPEs) / Equipments For Supervisor (electrical) and Line Man
Before starting any work at site, Personal Protective Equipments and special tools shall be provided to each
Foreman / Sub-Engineer or as deemed necessary to concerned staff deputed to work at site.
 Binoculars 1 No
 Tong Tester 1 No
 Stopwatch 1 No
 Magnifying glass 1 No
 Earth resistance Tester 1 No
 High Voltage Detector (Live Line Tester) 1 No
 (Handy type)
 Megger 1 No
 Measuring Tape 1 No

PPEs and tools shall be provided to every field person as per nature of job.
Personal Protective Equipments (PPEs) shall be in accordance with SOP/D/R&D/ESP/0601-2009.
Following are the minimum requirement of safety devices and special tools;
i. Rubber Gloves, Gauntlets and Rubber Mats(Class-2 Rubber Gloves for HT as per 5.1.2 & 5.1.3 in
addition to Rubber Sleeves)
ii. Full body harness with front position Safety Belt
iii. Safety Boots
iv. Insulated Safety Caps with chin strap (helmet with face shield for supervisory staff), Leather Protective
Gloves
v. Safety Clothing
vi. Safety goggles / Face shields
viii. Bamboo Ladders/MTL Ladders
ix. Manila Rope
x. Rain Coat
xi. Gum Boot
xii. Live Line Tester (Small one recently procured workable for HT and LT)
xiii. Discharge Rods
xiv. Ground rod ( Should be Light to facilitate the safety Culture )
xv. First Aid Tool Box to be provided in each MTL/ Trucks/Testing Van
xvi. Warning tapes and cones
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Standard Tools / equipments:


 Cutting pliers (insulated) - 8 inches 1 No
 Screw driver 8 inch (insulated handle) and 12 inches 1 No
 Manila rope 12 mm diameter 10 Meters
 Steel wire Brush 1 No
 Adjustable wrench - 8 and 12 inch each 1 No
 Hammer (ball pen) 1 lb 1 No
 Hoisters (For pliers, knife and wrench) 1 No
 Tool bag 1 No
 Pen knife 1 No
 Spanner Set - 12 pieces 1 Set
 Hack saw blade with insulated frame 1 Set
 Ratchet ( Small and Large) 1 No
 Test Lamp (single and double) 1 Set each
 Torch & battery cell 1 No
 Rubber Mat 1 No
 Gas Pliers - 10 inches 1 No
 Tester
 Fuse Puller
 Canvas Bucket with land line 15 m ( as per 4.9, 4.13 below
 Danger sign board for placing at road ( as per 5.1.1 below)
 Danger sign board for fixing at pole.
 Crimping tool (hand operated).

Rubber Insulated Gloves along with Rubber Insulated Sleeves and Rubber Insulated Mate shall be used
according to relevant KESC Standard Specification No. K/R&D/RG/50/2011

Safety Procedures and Precautions For Working on Poles & Towers


 Before climbing an elevated structure every employee shall first assure himself that the structure is
strong enough to sustain his weight safely.
 If poles or cross arms are apparently unsafe because of decay or unbalanced tensions of wires on
them, they shall be properly braced or guyed before they are climbed.
 For climbing over HT / LT steel tubular pole / steel lattice pole, the opposite side of the stray wire /
strut unit should be used.
 The workman shall avoid using conductors, insulators, insulator pin / clamp etc. for self support /
holding and should not rest on street light fixtures on the poles or structures.
 Supervisor should make sure that linemen are well equipped with required PPEs prior to the start of
work on poles / towers.
 Wire hooks would not be attached to linemen's belts or safety straps.
 In case if more than one person is required to work on elevated place / pole, the second man should
not start climbing until the first man reaches at safe position or when descending until the first man is
on the ground.
 Prior to start of work, the lineman should put his safety belt / full body harness around the pole or
some other suitable supports and make sure that the belt is properly secured. Care should be taken to
prevent the straps on safety belt coming in contact with anything that may open the snap and thus
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release the safety belt. Safety belts should not be attached to insulator pins, mains wire, guard wires
etc.
 Linemen's tools shall be so secured that they will not fall out of the tool belts. A lineman shall carry
only the minimum number of tools. All other tools shall be kept on the ground until they are required
and then lifted up by means of a material bag attached to a rope.
 Ordinarily no lineman shall work vertically below another lineman on the same pole except under
emergencies. When this condition is necessary, extreme care should be taken to prevent tools or
other objects being dropped upon the man working just below.
 When shifting wires and equipment from an existing to a new pole, the existing pole shall either be
locked with the new pole or guarded or both, as the condition may demand i.e. before start of work
i.e, before starting off loading.)
 Before a Lineman cuts an overhead conductor he shall make sure that it will fall at clear place. If there
is a possibility of the falling line may came in contact with another wire or causing other damages, it
shall be lowered to ground with a manila rope.
 All light equipment and tools to be used aloft shall be raised and lowered by means of a hand line and
canvas bucket, men on the ground should stand clear of overhead work to prevent being struck by
falling objects.
 In no case the tools / materials shall be thrown upward from ground to a lineman working at height,
nor shall lineman throw tools and materials from working place to the ground.
 No site working staff shall work in such a manner that his arms or any tools extend beyond the body of
pole.
 After completion of assigned job, all broken insulators or any other sharp edged material shall not be
left in open place/ along the walk way or in the location where the hazard of cutting feet could be
caused for humans or animals, the same should be taken back to area office for proper disposal.
 Extreme care should be taken when stringing wires across streets and highways, avoid interfering with
traffic which might cause injury to workmen or pedestrians. Danger signs should be placed on both
sides of the work location and where conditions warrant, flag-men shall be stationed.
 Hand lines, materials, tools or equipment shall not be scattered around streets, side walks, highways,
etc these must be kept in a neat and orderly manner simply to avoid accident.
 Conductor from ground / pole shall be raised or lowered respectively with a dry hand line and extreme
care shall be exercised to prevent them from coming in contact with live lines and equipment.

Safety Procedure & Precautions For Working On Overhead Lines


Working on Dead line and Equipment:
No person shall be allowed to work on line supports or conductors unless they are discharged and
grounded as follows:

 Prior to the start of work, the circuit shall be properly isolated and grounded at both ends. A danger
sign board to be fixed which should be clearly visible.
 After switching off the supply, before touching the lines, every one conductor shall be tested with
live line tester, in case there is no voltage then discharges the conductors by discharging rod (this
be done at the time of grounding / shorting with grounding rod). The discharging rods should be
kept at least two feet away from the body. This procedure is necessary in order to make sure that
the line to be worked on is actually the line that has been isolated. Rubber gloves along with
leather protecting gauntlet and rubber sleeve shall be used on both hands.
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 All the conductors shall then be shorted together and adequately grounded; this shall be done at
the points on each side of the place thereby creating a safety zone where the work is to be carried
out. Rubber hand gloves with leather gauntlets must be used while doing this work. Poles on which
work is to be carried out shall also be grounded.
 All phases shall be grounded even if work is to be carried out on one phase only.
 When work is to be carried out on lines of isolated conductors where grounding points are not
provided at point of work, temporary groundings should be used from the nearest available
ground.
 Where two or more teams are working independently on the same line or equipment, each team
shall properly protect themselves by placing their own independent ground.

Working on lines and equipment adjacent to live equipment or lines:


 When working near live lines or apparatus, each man shall take extreme care in moving from one
position to another.
 Where impractical to erect barriers between men at work and live parts within reach of their hands
and objects being handled, no work shall be carried out until & unless the live line is also made
dead & grounded.

Work on Double Circuit Overhead lines with one Circuit alive shall not be carried out
 Repair work on H.T. lines on poles where L.T is also running under H.T shall be carried out only after
switching off the L.T mains with ground / short effectively. Work on the L.T lines shall not be carried
out unless taking extreme safety precautions as already elaborated in clause 5.
 In case of LT Breaker fault, the LT mains at that PMT if back fed from near by PMT, then a danger
board must be fixed along with proper intimation at HT operation center from LT customer center.
 Some time HT is got off, for repair of LT at the same poles. If the LT emanates from the source
running on other feeder, then at the time of giving completion report, it must be reminded to
operation that LT is energized, so that L/M while going to remove short on HT must be aware of it
LT will be energized after removal of short on HT side.
 After completion of the job and prior to giving clearance for switching it ‘ON’, team in-charge shall
make sure that all short and ground are removed and all equipments used had been removed from
workplace.
 For further safety, lineman shall use the rubber insulating matting size 2.5'x4' and shall be placed
on conductor in front of him during work.

LT Leads Repair/Replacement work from Distribution Transformer to LT


Breaker/Distribution Box.
 Ensure that lineman to wear proper PPEs / SPEs, especially Rubber insulated gloves class’00’ with
leather protector gloves on both hands before start of work, and should fastened his full body
safety harness with front position safety belt, around the pole and make sure that the safety belt is
properly secured.
 IBC / VIBC Manager/Asst. Manager/Site In charge shall be responsible to supervise all the activities
at site, if lead replacement/repair is required at the incoming side of circuit breaker.
 Manager / Assistant Manager/Site in charge substation maintenance (SSM) shall be responsible to
supervise all the activities at site, if lead replacement/repair is required at the LT bushings of
transformer.
 After wearing HT Rubber Insulated gloves along with leather protector gloves on both hands &
other PPE’s, operation AE / site in charge will Switch ‘OFF’ PMT from HT side, and check for
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absence of HT Supply through HT Live Line Tester and isolate PMT by dropping HT Fuse Link (D.O.
Cutout).
 Switch ‘OFF’ LT Circuit Breaker to avoid any back feeding from LT circuit / Kunda. If no Circuit
Breaker is installed, pull out the all three LT HRC Fuses from Distribution Box/fuse box. Ensure
absence of supply at outgoing terminals of circuit breakers/DB through test lamp. Short & ground
on all LT circuits (all phases and neutral).
 Short & ground HT & LT side of PMT at bushing terminals.
 It is to be ensured by the site in-charge that proper earthing / grounding is available at point of
work , in case of non-provision/existence of appropriate grounding , temporary earthing should be
used from the nearest available ground.
 Now repair/replace the LT lead from Transformer LT Bushing to LT Circuit Breaker/Distribution Box.
 Remove all short & ground from both HT & LT sides after completion of job.
 Energize PMT from HT after getting clearance site in-charge & afterward switched ‘ON’ LT circuit
breaker.
 In case no Circuit Breaker is installed, first insert the LT HRC Fuses in Distribution Box/fuse box and
then get the PMT energized from HT side.

LT Lead Repair/Replacement work from LT Circuit Breaker to Distribution Box (DB)


& DB to LT O/H mains
 Ensure that lineman to wear proper PPEs/SPEs, especially Rubber insulated gloves class’00’ with
leather protector gloves on both hands & safety shoes before start of work, and should fastened
his full body safety harness with front position safety belt, around the pole and make sure that the
safety belt is properly secured.
 IBC / VIBC Asst. Manager/A.E/Site In charge shall be responsible to supervise all the activities.
 Put ‘OFF’ LT circuit breaker.
 Verify that there is no voltage at the outgoing side of the circuit breaker.
 Remove the LT fuses from DBs / Fuse Boxes connected with circuit breaker.
 Short & ground all Over head LT circuits (all phases and neutral)from outgoing side of DBs / Fuse
Boxes.
 It is to be ensured by the site in-charge that proper earthing/grounding is available at point of work
, in case of non-provision/existence of appropriate grounding, temporary earthing should be
used from the nearest available ground.
 After repair work ensure that all shorts and grounds have been removed, prior to clearance for
switching “ON” the supply.
 If circuit breaker is not installed / by passed, following shall be followed:
 After wearing HT Rubber Insulated gloves along with leather protector gloves on both hands
& other PPE’s, operation AE / site in charge will Switch ‘OFF’ PMT from HT side, and check
for absence of HT Supply through HT Live Line Tester and isolate PMT by dropping HT Fuse
Link (D.O. Cutout).
 Pull out the all three LT HRC Fuses from DBs / Fuse Boxes. Ensure absence of supply through
test lamp at outgoing side of DB. Short & ground all LT circuits (Phase & neutral).
 Short & ground (Phases & neutral) HT & LT side of PMT at bushing terminals
 It is to be ensured by the site in-charge that proper earthing / grounding is available at point
of work , in case of non-provision/existence of appropriate grounding, temporary earthing
should be used from the nearest available ground.
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 Now repair/replace the LT lead from Transformer LT Bushing to LT Circuit


Breaker/Distribution Box.
 Remove all short & ground from both HT & LT sides after completion of job.
 After getting clearance from site in-charge, insert the LT HRC Fuses in the DBs / Fuse Boxes
and then get the PMT energized from HT side.

Replacement of faulty LT Circuit Breaker


 Ensure that SSM Fitter to wear proper PPEs/SPEs, especially Rubber insulated gloves class’00’ with
leather protector gloves on both hands & safety shoes before start of work, and should fastened his
full body safety harness with front position safety belt, around the pole and make sure that the
safety belt is properly secured.
 Manager / Asst. Manager / A.E / Site In charge substation manager (SSM) shall be responsible to
supervise all the activities.
 After wearing HT Rubber Insulated gloves along with leather protector gloves on both
hands & other PPE’s, operation AE / site in charge will Switch ‘OFF’ PMT from HT side, and check
for absence of HT Supply through HT Live Line Tester and isolate PMT by dropping HT Fuse Link
(D.O. Cutout).
 Pull out the LT HRC Fuses from DBs / Fuse Boxes. Ensure absence of supply at the outgoing side of
BD/fuse box through test lamp. Short & ground all LT circuits (All phases and neutral). Short and
ground all LT circuits by IBC.
 Short & ground HT & LT side of PMT at bushing terminals.
 It is to be ensured by the site in-charge that proper earthing / grounding is available at point of
work , in case of non-provision / existence of appropriate grounding , temporary earthing should
be used from the nearest available ground.
 Now replace the faulty circuit breaker.
 Remove all short & ground from both HT & LT sides after completion of job.
 Energize PMT from HT after getting clearance from SSM team in-charge & afterward switched ‘ON’
LT circuit breaker to check it at ‘NO’ load.
 Switch ‘OFF’ circuit breaker & check for no voltage at outgoing side of the circuit breaker.
 Insert the LT HRC Fuses in the DBs / Fuse Boxes and then put ‘ON’ the circuit breaker.

Replacement of LT Fuses in DB
 Ensure that lineman to wear proper PPEs / SPEs, especially Rubber insulated gloves class’00’ with
leather protector gloves on both hands & safety shoes before start of work, and should fastened
his full body safety harness with front position safety belt, around the pole and make sure that the
safety belt is properly secured.
 IBC / VIBC A.E / Site In charge (Supervisor)/Line Man (LT) shall be responsible to supervise all the
activities.
 AE/Site In charge (Supervisor)/ Line Man (LT) will put ‘OFF’ the circuit breaker at PMT.
 Verify that there is no voltage at the outgoing side of the circuit breaker & pull out HRC fuses from
DBs / Fuse Boxes. Short & ground LT circuits (All phases & neutral).
 Site supervisor IBC/VIBC/ Line Man (LT) will Check physically LT over head mains, identify and
remove the fault, causing for blown off fuse & replace/change blown off fuses in DBs / Fuse
Boxes.
 Remove short & ground from LT circuits.
 Put ‘ON’ the circuit breaker.
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 If circuit breaker is not installed / by passed, following shall be followed


 After wearing HT Rubber Insulated gloves along with leather protector gloves on both hands &
other PPE’s, operation AE / site in charge will Switch ‘OFF’ PMT from HT side, and check for
absence of HT Supply through HT Live Line Tester and isolate PMT by dropping HT Fuse Link
(D.O. Cutout).
 Pull out the all three LT HRC Fuses from DBs / Fuse Boxes. Ensure absence of supply through
test lamp at outgoing side of DB. Short & ground all LT circuits (Phase & neutral).
 Short & ground HT & LT (Phases & neutral) side of PMT at bushing terminals.
 It is to be ensured by the site in-charge that proper earthing / grounding is available at point of
work , in case of non-provision/existence of appropriate grounding, temporary earthing should
be used from the nearest available ground.
 Site supervisor IBC/VIBC will Check physically LT over head mains, identify and remove the
fault, causing for blown off fuse & replace/change blown off fuses in DBs / Fuse Boxes.
 Now replace/insert the LT HRC Fusses in Distribution Box.
 Remove all short & grounds from both HT & LT sides after completion of job.
 After getting clearance from site in-charge, get the PMT energized from HT side.
 If fuse (s) instantly blow OFF again that will indicate a definite fault in the circuit.
 If the fuse (s) blow OFF with the passage of time, it indicates circuit over loading that can be
controlled by balancing/removing the over loading. Fuse shall be replaced after that.

Replacement of LT Fuses in Sub-Station


 Ensure that lineman to wear proper PPEs/SPEs, especially Rubber insulated gloves class’00’ with
leather protector gloves on both hands & safety shoes before start of work.
 AE Operation/ Supervisor (Electrical, Operation) will be responsible for the replacement of HRC
fuses, where as AE/site in charge IBC/VIBC will be responsible for the clearance of LT
circuits.
 Concerned IBC/VIBC will declare the fault of burnt out fuse(s) in sub-station after checking the O/H
LT overhead mains, for any possible wire broken wire entangle any wire shutting the main and
remove the fault, causing for blown off fuse & replace/change blown off fuses in DBs/Fuse boxes
 Clearance of LT circuit will be given by IBC/VIBC to concerned 11 KV operation center for the
replacement of LT HRC fuse(s).
 11 KV operation supervisor will wear the PPEs/SPEs before the start of the following operation:
 Put OFF the LT circuit breaker and ensure the absence of supply at outgoing side of the breaker / LT
panel. If LT circuit breaker is not installed/by passed, put OFF & lower the trolley of 11 KV (HT)
switch of local transformer. Check the absence of HT supply at transformer through HT live line
tester / LT with test lamp.
 Short & ground All LT bus bars (Phases & neutral).
 Replace the LT HRC Fuses and remove the short / ground from bus bar.
 Put ON the LT circuit breaker/switch ON the transformer from HT side.
 If fuse (s) instantly blow OFF again that will indicate a definite fault in the circuit.
 If the fuse (s) blow OFF with the passage of time, it indicates circuit over loading that can be
controlled by balancing/removing the over loading. Fuse shall be replaced after that.
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Repair of LT mains jumpers


 Ensure that lineman to wear proper PPEs/SPEs, especially Rubber insulated gloves class’00’ with
leather protector gloves on both hands & safety shoes before start of work, and should fastened his
full body safety harness with front position safety belt, around the pole and make sure that
the safety belt is properly secured.
 IBC / VIBC A.E / Site In charge / Line Man (LT) shall be responsible to supervise all the activities.
 Put ‘OFF’ the LT circuit breaker and check supply at outgoing side of circuit breaker with live line
tester / test lamp.
 If circuit breaker is not installed / by passed, following shall be followed:
 After wearing HT Rubber Insulated gloves along with leather protector gloves on both
hands & other PPE’s, operation AE / site in charge will Switch ‘OFF’ PMT from HT side, and
check for absence of HT Supply through HT Live Line Tester and isolate PMT by dropping
HT Fuse Link (D.O. Cutout).
 Pull out the all three LT HRC Fuses from DBs / Fuse Boxes. Ensure absence of supply
through test lamp at outgoing side of DB. Short & ground all LT circuits (all Phase &
neutral).
 Short & ground (all Phases & neutral) HT & LT side of PMT at bushing terminals
 It is to be ensured by the site in-charge that proper earthing / grounding is available at
point of work , in case of non-provision/existence of appropriate grounding , temporary
earthing should be used from the nearest available ground.
 If street light conductor is also running with LT mains, it must be switched ‘OFF’ if fed from any
other LT circuit / DB.
 Short and ground overhead mains (all Phases & neutral) at both sides of pole/shackle point.
 For enhanced safety, lineman shall use the rubber insulating matt size 2.5’x4’ which shall be placed
on conductor in front of him during work.
 After repair work, insert all fuses in DBs/Fuse Boxes.
 Ensure that all shorts and grounds have been removed.
 Switch ON the circuit breaker/PMT.

Repair of service connection jumper (Live line)


 Individual service connection jumpers/ wires are to be repaired on live line, therefore, extreme care
shall be taken during complete activity & lineman must ensure to wear PPEs especially rubber
insulated gloves class ‘00’ with leather protector gloves on both hand, safety shoes, helmet, safety
belt, goggles etc.
 In case of multi storey/commercial building the service connections through cable service has to be
isolated from nearest possible isolation point like Tee Off jumper/ removal of fuses from DB or
substation LT panel/ switching ‘OFF’ circuit breaker etc.
 IBC/VIBC Supervisor/ Site In charge/Line man shall be responsible to supervise all the activities.
 For enhanced safety lineman shall use the rubber insulating matt size 2.5’x4’ which shall be placed
on conductor in front of him during work.

Installing or Removing DOL Meters


 IBC / VIBC meter fixer/site in charge will be responsible for all activities.
 Rubber gloves with leather protectors shall be worn when installing or removing energized electric
metering equipment.
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 When connecting or disconnecting energized service conductors in metering equipment, rubber


gloves shall be worn.
 A face shield with safety glasses is mandatory protective equipment for employees working on or
near energized metering equipment under the following conditions:
 When installing, changing, removing or testing energized meter and related equipment.
 When connecting or disconnecting, in an enclosed space.

Responsibilities of Supervisor(HT/LT):
Supervisor shall brief the following to field staff before the commencement of work to be executed:

 About description of job/activity to be performed or executed.


 SOPs / work instruction for execution of job and also brief to perform assigned job as per KESC
Standards / Specification / work practice.
 The field staff for possible hazards & associate risks with the task / activity.
 Shall involve and discuss with the participants their feedback & invite suggestions for improvement
of safety during performing of task / activity.
 The mandatory usage of PPEs during the job.
 Shall check & verify all mandatory tools / PPEs are available, appropriate & fit for purpose.
 Shall ensure that all field workers are competent, aware of the task; understand their roles /
responsibilities & familiar with the hazards & controls to be implemented.
 Employee supervising or directing the work will be held responsible for enforcement & shall hold
off part or all the work until the required PPE’s are in place.
 In no circumstances shall the lineman be allowed to work wearing only rubber or leather protector
gloves. To attend any fault both Rubber insulated gloves and leather protector gloves shall be worn
on both hands.
 Karkun / helper shall not be allowed in any case to work as a line man.
 HT & LT short & ground to be removed by HT & LT gangs respectively.
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Chapter 11 - Restoration of 11-KV Feeders after Tripping


from Grid Station
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INTRODUCTION:
This document is developed as Standard Operating Procedure for restoring the tripped 11-KV feeders, so as
to avoid repeated “Tries” on the faulty feeders and flow of convulsive fault currents in the Grid Power
Transformer that may ultimately cause severe damages to the windings. This SOP is to be adopted and
followed by 11KV Distribution Operation, Grid SBO and LDC Engineers.

SCOPE
The power transformers installed in the Grid Station have crossed their maximum life and ages up to 40
years or more. The EHT system has now become redundant and it can’t be tried now and then due to the
constraints of 11 KV system. In order to manage all mentioned issues a team was formed that included all
the GMs of HT, personnel from LDC and Grid and few senior staff with vast knowledge of network. For the
same purpose, Standard Operating Procedure (SOP) is developed to avoid repeated tries on the faulty
feeders.

The SOP will be advantageous in a way that it will secure our system and the equipments installed in the
network. This will not only increase the reliability of the system but it will also ensure the safety of
equipment’s as well as the personnel working on them.

APPLICABILITY
11-KV Operation Controls, Area Operation Centers and LDC.

PROCEDURE
1. Situation – 1
In case of 11-KV feeder tripping at G/S with following condition:
a. Phase to phase relay indications,
b. RYB E-inst / time delay indications,
c. Any relay indication with heavy surge
d. Power Transformer tripped either from 11 KV or 132 KV or both sides then,

Action: Grid - SBO will inform LDC and HT Operation Shift Engineer. LDC Shift Engineer will
then inform SBO not to put “ON” the feeder, even if the HT Operation Shift Engineer
requests for a “Try”.
The status of Protection Relay shall be properly recorded by SBO at the VCB of feeder, 11KV
I/C of transformer and 132 KV breaker.
For switching “ON” such feeder, HT Operation Engineer will ensure one of the following
actions and will inform LDC through E-Mail/SMS. The LDC Engineer will inform SBO for
putting “ON” such feeder on receiving clearance from Operation Engineer and will reply to
operation engineer accordingly.

 EFI at the incoming of feeder in SS/RMU found operated.


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 Incoming of OCB/VCB of feeder found operated.


 Main cable of feeder has been back fed and found okay. (At the time of back feeding
the Main cable, the trolley at the grid must be at first stage position.)
 Main cable of feeder has been pressure tested by UGM testing gang and has been
found Okay.
 If Operation Engineer informs LDC that the fault has been traced / found at the
outgoing loops & has isolated and he wants to get the feeder to be put - ON, then the
Operation Engineer will inform LDC Engineer through E-Mail/SMS for switching the
feeder “ON” and LDC Engineer will inform the SBO for putting “ON” such feeder on
the clearance of Operation Engineer.
 If even then the feeder tripped again it will be treated as Main Cable Fault.
 In case of point (5.1-d), LDC Engineer will also seek the clearance from respective GSM
and Protection.

2. Situation – 2

 In case of tripping of an 11-KVfeeder with single phase (Time/Instantaneous) relays


indications and if EFI at the incoming of the feeder has found operated (or the
incoming OCB/VCB of the feeder has found operated in the S/S) the feeder switching
“ON” from the Grid may be attempted on the instructions of HT Operation engineer
after switching “OFF” the incoming OCB/VCB of the feeder at the S/S, if not tripped. If
feeder trips again, Main cable fault will be declared.
 However, in case of Rain / Emergency situation, any feeder tripped without surge and
single phase relay operation, feeder may be tried by Operation engineer.
 On non-operation of EFI at feeder terminal end, it shall not be tried. However, in case
of its non-availability, previous SOP shall follow till they are installed on the remaining
feeders ASAP.
 There will be few exceptions for the rural/far flung areas, for which feeder trial shall
be on case to case basis by Distribution Dept.

3. Situation – 3

In case the feeder trips “OFF” again, following procedure will be adopted.

3.1 SINGLE CABLE FEEDER AT GRID STATION.

In case of single cable feeder from the G/S, If EFI at the incoming of the feeder is found Operated
(or the incoming OCB/VCB of the feeder is found operated) then it means that the main cable is
sound, then

3.1.1. Switch “OFF” the outgoing loops on which EFI has operated.
3.1.2. Switch “OFF” the incoming of feeder, Local Transformer and all outgoing switches.
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3.1.3. Get the feeder Switch “ON” from the G/S, after checking the Grid VCB of the feeder by the SBO
at the G/S.
3.1.4. Check all the suspected loops on the basis of EFI operated.
3.1.5. Isolate the faulty section of the network.
3.1.6. Switch “ON” the loops one by one to normalize the Network.
3.1.7. If EFIs have not installed at the outgoing loops, check all the loops thoroughly to trace the faulty
section, isolate the faulty section and then put “ON” the healthy loops one by one, this may
again cause tripping of the feeder, if the faulty section was not traced or due to multiple faults,
then repeat the above procedure more carefully.
3.1.8. If while going through step (3.1.7) feeder tripped again then step (3.1.1 ~ 3.1.6) will be followed
according to relay operation.

3.2 DOUBLE CABLE FEEDERS AT GRID STATION.


3.2.1. In case of double cable feeder (A+B) at the G/S, one of the feeders (Say A) will have EFI

3.2.2. Installed at the G/S and on tripping of the feeder the SBO will inform whether EFI has operated
or not. In case the EFI gets operated the fault will be in the feeder “A” side and if the EFI did not
operate at the G/S then the fault will be in the feeder “B” side, therefore, operation staff may
accordingly be dispatched to attend the tripping of the feeder.

3.2.3. If the feeder trips with EFI operated at the G/S, then fault is at feeder “A” side, get EFI at the
incoming of feeder “A” be checked, if it is found not operated, then declare the main cable of
feeder “A” faulty, get the faulty cable isolated and normalize the healthy one, otherwise if the
EFI is found operated then follow the instruction (3.1.2) to (3.1.7).

3.1.21. If the feeder trips without operating EFI at the G/S, then fault is at feeder “B” side. Get EFI at
the incoming of the feeder “B” be checked and if it is found not operated then declare the main
cable of feeder “B” faulty. Get the faulty cable isolated and normalize the healthy one,
otherwise if the EFI is found operated then follow the instruction (3.1.2) to (3.1.8).

3.1.22. In case EFI is not installed / faulty / timed-out due to delayed attendance, instructions (3.1.1) to
(3.1.6) will be followed by Operation engineer.
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Chapter 12 - LT Service Cable fault


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LT Service Cable fault(U/G)

Consumer Residential (Individual)

Case I load below 40 KW


In case of fault existing cable service to individual consumer upto meter temporary supply may be restored
leading to repair/replacement of cable in due course of time.
The cable size is to be co-ordinate with Sanctioned load of consumer. No cost is to be recovered from
consumer if the cable size is as per sanctioned load.
Any Change in size what so ever will be treated as load regularization case and to be dealt with NC.

Case II load Above 40 KW


After restoration of temporary supply, case may be forwarded to NC for installation of CTO meter under
DOL to CTO conversion cost/expenses in this case is to be recovered along with revised SD/SDC (if
applicable)

LT Service O/H (ABC/PVC)


Case I meter at consumer premises

All faults related to consumer supply restoration are to be rectified on KSEC account, upto meter including
replacement of service cable if required.

Case II Meter at Pole (in meter box or individual)

a) If the service is provided through twin/four core PVC, cost of repair to the cable is to be borne by
KESC, However in case of replacement of service cable (either 2 core or 4 core) is to be equally shared
by KESC/consumer subject to limitation of sanctioned load.
b) Same phenomena will also apply on ABC cable irrespective of size/cores.
c) Any alternation to existing service point/meter location is chargeable job.

Multistory Full Residential

a) All work related to LT/HT supply restoration till meter is to be borne by KESC.
b) In case of fault damaged to all meters in small/large bus bar arrangement, damaged meters with bus
arrangement is the responsibility of KESC.
c) Individual burnt out/damaged meter is to be replaced at the cost of consumer after fulfillment of
necessary formalities in FMR (Faulty Meter Report).
d) Any addition/alteration in sanctioned load/Service size is to be charged from applicant as per policy
(NC) manual refers.

Dismantling of Service (Residential)

a) Applicant premises is to be surveyed needs dismantling of service for any reason.


b) Meter reading to be noted for dues clearance prior to issuance of estimate for dismantling the service
c) Complete details are to be recorded of meter dismantled and scrap discount may be accounted for
while preparing estimate for dismantling the service.
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Re –installment of Residential service

a) Consumer premises is to be surveyed with complete building plan.


b) If the covered area is increased, connected load will also be increased.
c) Application for re-installment is to be diverted to NC for evaluation of load & issuance of estimate/SD
accordingly.

Multistory (Residential Cum Commercial)

a) In case of service cable fault the cost of cable repair/replacement to be recover from the commercial
customer as share money as per load and KESC policy where as residential consumers are not to pay
the share money.
b) In case of small/Large busbar arrangement damaged at multistory the supply of residential customer
will be immediately restore by KESC on temporary bases where as the new scheme or placement of
small/Large busbar arrangement will be execute by KESC with recover payment share money as per
load from commercial consumers.

Multistory (Purely Commercial)

a) All HT Cable fault and HT over head fault for multi story commercial building is the responsibility of
KESC.
b) Dedicate PMT of commercial building in case of PMT fault the replacement of PMT to be carried out
on 100% payment case from the commercial customer
c) All bus bar

Industrial Consumer

LT Bulk supply
Any LT B/S consumer either feed through Sub-Station or through PMT is to be as DDS(Dedicated
Distribution system) Consumer at all expenses towards fault rectification/replacement what so ever is to
be fully charge from consumer. Along with L & T and supervision charges.

LT Bulk Supply through Dedicated PMT

a) In case of radial feed of dedicated PMT through HT cable all expenses in maintaining supply is to be
recovered from consumer i.e. fault in HT/LT cable PMT etc.
b) If supply through a PMT come in the 11 KV ring then case of HT cable fault KESC to take care for all
work related to ratification of cable fault, However PMT and allied equipment including LT cable upto
the meter is to be borne by the consumer including L & T and supervision charges. Subject to the
connected load in accordance to the sanctioned load any increase in sanctioned load, matter may be
forwarded to relevant NC for regularization
c) Any damage to the Energy meter and allied accessories (CTs, wiring etc) all expenses towards
replacement of damaged equipment will be rest on consumer.
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HT Bulk Supply

Industrial consumer.
All work related to restoration of supply in rectification of fault/Replacement of damage/Fatigued
equipment in HT cable, Joint/termination is to be the responsibility of consumer and complete cost
including L&T and supervision is to be recovered from consumer prior to the execution.

Following faults in HT bulk supply are the responsibility of bulk supply customer and all expenses including
material / equipment L & T & Supervisor is to be borne by the consumer:

I. Fault in 11KV OCB / VCB


II. Fault in 11KV CT / PT
III. Fault in 11KV cable / bus bar side shrouds damage
IV. Faults in HT cable from 11KV OCB / VCB to consumer HT switch room
V. 11KV cable end damaged in consumer B/S switch
VI. Metering equipment at 11KV OCB / VCB fault
VII. In case of complete damage to OCB / VCB new VCB / OCB is to be delivered by consumer as per
latest KESC specification with all relevant / allied material necessary testing / commission /
shutdown charges will be recover from consumer prior to the execution of job
VIII. In case of damage to PT / CT, no bypass arrangement is permitted and consumer will be directed to
deliver CT / PT for replacement to the damage one leading restoration of supply all charges in this
regard for replacement of CT / PT is to be paid by the consumer in advance
IX. In case of damage to the complete panel or damage to CT / PT concerned IBC personal may be
called upon by operation to witness / ___________ all damages with date & time. In no case back
plate of dedicated 11KV panel is to be open without presence of IBC personal the later will tear OFF
KESC bond paper seals and will allow operation to proceed further
X. Supply restoration after replacement of damage panel / CT / PT is subject to sealing / bonding of
back plate, front plate by IBC personal. Dismantling of GD S/S in applicant premises

Dismantling of Sub-Station
a) After receipt of application for the dismantling of sub-station within the consumers premises, the
applicant should be asked to sign a MOU regarding allocation of new space for the sub-station of KESC
standard dimensions along with payment of all new material to be installed after completion of civil
work for sub-satin
b) General Distribution sub-station

1. In case general distribution system application request to dismantled the KESC sub-station as the
sub-station is located at the premises of the applicant

2. Request of consumer can be consider with following conditions:

i. Consumer provide alternate arrangement / location of new sub-station


ii. The existing HT network of sub-station means HT cable, 11KV panels, transformers, LT panel, LT
cable etc will be shift at alternate location near to the sub-station. In such case the proposal for
alternate arrangement will be initiated by the IBC / VIBC with the clearance of dues etc,
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whereas the proposal or alternate arrangement for installation of RMU, PMT, HT LT cable
shifting etc with the suggested by 11KV operation under 100% self fianace basis for applicant

iii. In case of new location with existing approved loading position of consumer for sub-station is
made by consumer then all the material / equipment cost will be borne by the consumer for
energization new sub-station with dismantling of existing temporary arrangements

c) In General Distribution Sub-Station if Applicant Enhance Load or Construct Multistory Building.


Application for the re-installment of service is to be referred to NC (above 50KW) for load assessment
& further processing in the matter during the process of building construction, the applicant can get
temporary service. All details related to allocation of S/S is already elaborated in manual / SOP for new
S/S.
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GLOSSARY OF TERMS/ABBREVIATIONS

HT = 11 KV
G/S = Grid Station
LDC = Load Dispatch Centre
VCB = Vacuum Circuit Breaker
SBO = Switch Board Operator
EFI = Earth Fault Indicator
OCB = Oil Circuit Breaker
L/O = Cable lead open
J/O: = Jumper open
AOC: = Area operation centre
S/S: = Sub-station
TL: = 11KV Switch OCB trolley lower
TFS: = 11KV Switch VCB trolley first stage
E: = Equipment like isolator / RMU grounded or earthed
G/S: = Grid station
SBO: = Grid station switch board operation
TBT: = Tool box talk
S/D: = Step down
WDB: = with danger board
S. SK L/M: = Semi-skilled line man
OCR: = Operation control room
B&G: = LT fuse base & grip
O/H: = Overhead
D/E Wire: = Double earth wire

Definitions

Approved
When applied to articles of protective equipment means that these articles have been specified for use by
permanent / contract & outsourced employees as per HSEQ

Authorized Person
An Authorized person is a person authorized to carry out such duties incidental to the distribution and
use of electrical energy, the nature of which shall depend upon the technical knowledge and experience of
the individual and he shall not be less in authority than a lineman, jointer, fitter and mechanic.

Earth
Earth means the conducting mass of earth or a conductor / strip / wire connected to it through very small
impedance.

Electrical Equipment
It means all the electrical apparatus pertaining to the distribution and utilization of electrical energy.
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Emergency
Emergency means that an unusual condition exists which endangers life and or property.

Employee
Employee means a person who is in receipt of pay, salary and other benefits from the company time to
time in lieu of services render by him.

Hazard
It is any unsafe act or unsafe condition that may lead to injury of persons or damage to property.

Isolated
It means physically disconnected from all possible sources of supply.
Permit to Work
It means a form of declaration issued by an Authorized Person (PSC) to another Authorized Person (sub
distribution) for a work to be carried out on any equipment in normal & break down conditions.

Power System Control


It means the main controlling agency which controls & coordinates all switching operations of entire
network (HT & LT distribution) of KESC including issue of Permit to Work

Protective Devices
It means equipment specially designed for the protection of workmen and includes fire extinguishers also.

Qualified
Qualified means any person who has adequate knowledge of the hazards involved in any operation.

Working Party
It means the persons under the immediate supervision of an Authorized Person.

Permit to Work System


Permit to work system provides in-built safety to workmen engaged in electrical work.

Working on Height
Before any work is began on any pole or tower of a high voltage overhead line, which is adjacent and
parallel to any other high voltage overhead line with conductors “alive” or any pole or tower which
supports, more than one set of high voltage conductors “alive” the following special precautions, in
addition to the foregoing, shall be taken in every case:
i. The authorized person in charge of the work shall ensure that each workman who is to work on the
poles or towers is definitely informed and thoroughly understands on which set of conductors the
work is to be carried out.
ii. A “red” flag / Caution Tape (or lamp at night) which are available with maintenance crew, shall be
displayed on the side of the pole or structure on which the conductors are “alive”.
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iii. Work shall not be performed on any higher position of tower / line when a line below is energized.

Work on High Voltage Apparatus


Before commencing any work of repairs, alterations, extensions, additions or cleaning of high voltage
apparatus, the following operations shall be carried out in sequence.
i. The apparatus or cable or transmission line shall be switched out and isolated from all points supply
under the direction of the authorized person.
ii. The switches, isolators and control links shall be locked in position by the keys provided for the
purpose.
iii. Safety Tags shall be placed at all points where apparatus can be made alive.
iv. All apparatus shall be discharged to earth and efficiently connected to earth near all points from
which supply could be connected to it or between such points and the place of the work. All earthing
shall be done by the approved methods. The earthing leads used for earthing shall be of adequate
cross section according to voltage levels to enable passage of the fault current without fusing. Safety
Tags shall be removed by an authorized person.
v. Earthing shall also be carried out at the point of work by means of temporary earths on each phase
and in no case shall the temporary earths be removed from two phases simultaneously while the
work is being carried out.
Working on Lines under Adverse Weather Conditions
In the event of the near approach of lightning or thunderstorm all work on overhead lines shall cease
immediately.

Grounding of Lines and Equipments


i. Before doing any work on dead lines or equipment where there is a possibility of their becoming
energized from any source, such line or equipment should be short circuited and grounded between
the location of work and all possible sources of energy.
ii. Conductors to be grounded should be checked for potential by an approved method before the
ground is installed.
iii. Temporary grounding cables shall be flexible stranded copper not less than No. 10 and shall be
equipped with approved clamps at each end.
iv. Grounding cables should be inspected before each use.
v. When grounding lines or equipment, the connection to the ground shall be made first and that to
the circuit or equipment last. In removing grounds, first remove the connection to the circuit or
apparatus and then remove the ground connection. Insulated hot-sticks should be used in making
the ground connection to the circuit or apparatus.
vi. Grounds shall be placed on all phases even if work is to be carried out on one phase only.
vii. For work on the line, ground shall be placed at nearest tower on each side of the point of work, but
in no case should earths be more than six spans apart. As an additional safety measure, if possible, in
addition to above grounds, line should also be grounded on the tower where the work is to be
carried out.
viii. When work is to be carried out on lines of all-insulated construction and grounding point is not
provided at point of work, temporary grounds shall be connected at point of work to an efficient
portable earth stake driven into the ground. The line shall also be grounded at the nearest line
grounding point on either side of the point of work.
vii. Where two or more crews are working independently on the same line or equipment, each crew
shall properly protect themselves by placing their own temporary grounds.
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Line Work on Poles


i. Before climbing any elevated structure, every employee shall first assure himself that the structure
is strong enough to sustain his weight safely.
ii. If poles or bracket are apparently unsafe because of decay or unbalanced tensions of wires on them,
they shall be properly braced or guyed before they are climbed.
iii. Linemen shall wear their safety lines while working on the poles and towers.
iv. Wire hooks shall not be attached to linemen’s belts.
v. Safety straps should not be placed above the top cross arm when it is at the top of the pole.
vi. Full Body Safety Harness

Working in Sub-Stations
i. Safety Tags should be placed on all enclosures of high voltage equipment and wherever necessary
warn persons of the presence of high voltage equipment. The different safety audits to be
conducted as per guidelines provided in document
ii. Gates in switchyard fences and doors to switch gear and other enclosures containing live equipment,
or other hazards, should be kept locked at all times except when Authorized Person entered for
working inside.
iii. When carrying ladders, pipes, conduits, reinforced rods and other long material in to stations,
Switchyards, switch gear rooms and other places where there is a danger of touching the live parts,
the material should be held by two men, one at each end, and carried in the hands and not on the
shoulders.
iv. When working in the vicinity of circuit breakers or buses use every precaution to avoid injury from
arcing.
v. Area is to be guarded off wherever possible, where men are working on HT equipment.

Working on Transformer
i. When work is to be carried out on a transformer, both low and high tension breakers and isolators
shall be opened. Similarly, during isolation of transformers to which potential transformers are
connected, such potential transformers shall be isolated.
ii. Before starting any work on a transformer installation, it is important to check carefully for back
feed, abnormal voltage or other dangerous conditions. Unusual circuit conditions may exist which
require special consideration.
iii. Whenever transformers are replaced, the new transformer should be checked carefully for voltage,
polarity and phase sequence before taking into service.
iv. Area should always be cordoned off & Safety tagging should be done prior to starting the job on
transformer.

Working on Instrument Transformers


i. The cases of all instrument transformers should be grounded.
ii. Current transformers secondaries should never be open circuited when current is flowing in the
primary.
iii. The secondary circuit of current transformers should be connected to ground at all times when the
transformer is in service.
iv. Potential transformers secondaries should never be shorted.
v. The low voltage winding of potential transformers should always have one side permanently and
effectively grounded.
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Working on Pole Mounted Sub-Stations (Distribution Transformer)


The following precautions shall be observed in case of carrying out work on the pole-mounted sub-
stations (i.e. Distribution transformers):

i. The work shall be carried out under a permit to work.


ii. Before changing or replenishing oil or painting, all exposed live parts of the transformers shall be
disconnected.
iii. While working on poles that have lightning arresters installed on them, the workman shall avoid
touching lightning arresters and lightning arresters jumper.
Working on Circuit Breakers
i. Mechanical blocking, wherever necessary, to prevent unauthorized movement of the mechanism is
installed.
ii. In OCBs trip-free feature should be blocked.

Working on Metal Clad, Switch Gear and Control Panel


i. While working on manually operated panel mounted circuit breakers when the operating handle is on
the front and the circuit breaker is on the rear of switchgear or on another panel, a danger notice
shall be placed on the handle.
ii. When the work is to be carried out on the bus bars spouts the following operations shall be carried
out.
 The section of bus bars on which the work is to be carried out shall be made dead and shall be
isolated from all points of supply.
 The isolating arrangements and the shutters of live spouts shall be locked so that they cannot
be operated.
 The bus bar shall be earthed with approved earthing equipment at a panel other than at which
work is to be done and the isolated section of the bus bars.

Working on Outdoor Structure

Bus-Bars
i. While working on the outdoor structure at a height more than 3 meters from the ground level, safety
equipment such as safety belts, handling, etc. should be used.
ii. No person shall stand directly below the place of work when the work is in progress in the outdoor
structure to avoid any tools or bolts or nuts or clamps etc. falling on their heads.
iii. Helmets should be invariably used while working on the outdoor structures, on the outdoor
structures, both by the men stationed at the ground and those on the structures.

Capacitors
i. Every capacitor shall be treated as hot until proved otherwise. Capacitors stores energy and are not
necessarily dead when disconnected from the line. Once charged, a capacitor may retain its charge
for several hours after it has been disconnected.
ii. When a capacitor is to be worked on, first open all cutouts or disconnecting devices to the capacitor,
then wait for at-least five minutes for the internal resistors to reduce the voltage. Next, using the
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hot stick (discharge rod), short circuit and ground all terminals of the capacitors. These terminals
should remain short circuited and grounded while work is being done on the capacitor.
iii. To bring the capacitor banks back into service, first remove the jumpers with hot sticks, and then
close the cutouts.
Lightning Arrestor
i. No work shall be done on the lightning arresters unless it is disconnected from the line circuit and
grounded at both the lines and ground terminals.
ii. It’s the indication that fault occurred at the outgoing loops of the feeder’s cable or other
equipments like 11KV switches, RMU, S/S Bus Bar, HT O/H Main fault, PMT, Local Transformers of
Sub-Station.
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Section B – SSM
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Chapter 1 - Replacement of LT Breaker, DB, Leads or DO


Cutout
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OBJECTIVE
To assure replacement of one or more of the following on 11 KV network distribution in line with all safety
policies and procedures:

 LT Breaker
 DB
 HT – LT Leads
 DO Cutout

SCOPE:
This SOP shall apply to all SSM (KESC and 3rd party) employees working on replacement of LT Breaker, DB,
HT- LT Leads, and DO Cutout.

ROLES & RESPONSIBILITIES:


1. SSM Site Supervisor:
 Take confirmation of shutdown and isolation (HT/LT) from AOC and LT supervisors.
 Supervise all activities at site and implement all safety procedures including TBT procedure (SP-
010), Circulars 16, Circular 29 and Line Isolation SOP.
 Check license and certification of MTL driver.
 Before energization of newly installed LT Breaker, DB and / or DO cutout, ensure that the leads
are connected properly.
 In case of newly installed LT breaker, also ensure the following:
a) Phase sequence of LT leads
b) Breaker current setting is fixed at 70%
c) Neutral lead and PMT body earth is connected
d) Pole structure of transformer is properly earthed
e) Lock the door of LT breaker housing
 After completion of work, give clearance to AOC supervisor.

2. LT Supervisor:
 Before starting of work, give isolation from LT side and short & ground all sides as per Line
Isolation SOP.
 After completion of work, remove all short and grounds from LT side.
 In case of installation of LT breaker, give clearance to AOC supervisor from LT side.

3. AOC Supervisor:
 Before starting of work, give shutdown from HT side and short & ground all sides as per Line
Isolation SOP.
 After completion of work, remove all short and grounds from HT side.
 Energize the line and put LT breaker ON.
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4. SSM Sk. Fitter / S Sk. Fitter:


 In case of replacement of LT breaker, Sk. Fitter / S Sk. Fitter to remove connections from both
sides of LT breaker, replace LT breaker with new one and reconnect connections from both
sides.
 In case of replacement of DO cutout, Sk. Fitter / S Sk. Fitter to remove connections from both
sides of DO cutout, replace DO cutout with new one and reconnect connections from both
sides.
 In case of replacement of DB and leads (Leads from Bushing to Breaker only ) , Sk. Fitter / S Sk.
Fitter will repair / Replace the Leads after IBC will remove connections from both sides of DB ,
however DB will be replaced by SSM.

5. SSM Karkun:
 Assist Sk. Fitter / S Sk. Fitter.
 Should not perform work without instruction of SSM site supervisor, Sk. Fitter or S Sk. Fitter.

6. AM – SSM & AE -SSM


 AM to prepare debit note(s) and gate pass While AE can make gate passes only.

7. A.E /A.M /Manager--- SSM


 AM / Manager will Sign on debit note and gate pass while AE can sign on gate passes only..
 Managers will acquisition and allocation of materials to gang.

8. GM – HT:
 GM – HT to oversight all above mentioned activities and fulfill requirement of tools, equipment,
PPEs, SPEs and logistics for field staff along with material management.
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PROCESS FLOWS / PROCEDURE:


Gang reached site with tools, PPEs, SPEs and logistics

On-site TBT conducted at site

Written clearance given to SSM site supervisor who verifies shutdown

Gang starts work after mounting MTL

Is job for LT Remove connections from both


Breaker
Yes
sides of LT breaker
replacement?

Replace Breaker
No
Connect both sides of LT breaker

Remove connections from both


Is job for DO Yes
cutout
sides of DO cutout
replacement?

Replace DO cutout

No Connect both sides of DO cutout

Is job for DB / Yes Remove connections from both


leads sides of DB / leads
replacement
?

Replace DB / leads

No Connect both sides of DB / lead

Give clearance to AOC

Remove short & ground from all sides (HT & LT) by AOC from HT and IBC from LT

Energize the line Put LT breaker ON END


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PERFORMANCE MANAGEMENT (TATs):


TAT for LT breaker replacement = 3 hours
TAT for DO cutout replacement = 3 hours
TAT for DB replacement = 3 hours
Time taken to complete task to be recorded as per form A.
Performance of SSM for LT breaker replacement to be measured with Form B on Annexure.
TAT for each SSM job is from shutdown till clearance to AOC.
TOOLS, EQUIPMENT& LOGISTICS:
Tools & Equipment:
a) Cutting Pliers (insulated)
b) Screw Driver (insulated handle)
c) Spanner Set (12 pieces)
d) Socket wrench set
e) Hacksaw Blade (with insulated frame)
f) Tool bag & other necessary tools

PPEs & SPEs for Field Staff:


Before starting any work at site, Personal Protective Equipment and Special tools related to workshall be
checked comprehensively by concerned deputed staff. Some Tools normally used are listed below:-
a) Uniform
b) Safety shoes
c) Helmet with chin strip
d) Rubber and leather gloves
e) Live line tester
f) Full body harness with front position belt
g) Danger sign board (safety tape) for placing at road
h) Emergency light (depending upon time of day)
i) Rain coats &gum boots (depending upon weather)

Logistics:
MTLs will be required. All vehicles should pass the fitness criteria as per KESC fleet workshop:

GANG FORMATION &COMPETENCY:


Gang to be formed with respect to assigned KESC designations as stated below:
a) 01 Supervisor (A.E, EMO, Sub Engineer)
b) 01 Fitter
c) 01 Semi Skilled Fitter
d) 02 Karkuns

MATERIAL MANAGEMENT:
LT Breaker, DO Cutout & DB:
 Maintain inventory record of LT breakers, DO cutouts and DBs at SSM store and update movement,
usage and record.
 Analyze usage of LT breakers, DO cutouts and DBs. Identify and state requirement of critical items.
 Track issuance, usage and receiving of material.
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Chapter 2 - Replacement of CT and PT and Cleaning of


Carbonized HT Busbars
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OBJECTIVE:
To assure replacement of one or more of the following in substations on 11 KV network distribution in line
with all safety policies and procedures:
 Replacement of CT / PT
 Cleaning of Carbonized HT Busbars

SCOPE:
This SOP shall apply to all SSM (KESC and 3rd party) employees working on replacement of CT / PT and
cleaning of carbonized HT busbars

ROLES & RESPONSIBILITIES:


1. SSM Site Supervisor:
 Take confirmation of shutdown and isolation (HT and LT) from AOC supervisor.
 Supervise all activities at site and implement all safety procedures including TBT procedure
(SP-010), Circulars 16, Circular 29 and Line Isolation SOP.
 Check license and certification of truck driver.
 Before energization of newly installed CT / PT, SSM site supervisor to ensure the following:
 Back plates are installed.
 Existing panel is earthed.
 After completion of work, give clearance to AOC supervisor and inform concerned billing /
meter section.

2. AOC Supervisor:
 Before starting of work, give shutdown from HT side and short & ground all sides as per Line
Isolation SOP.
 Short and ground transformer HT bushing.
 After completion of work, remove all short and grounds.
 Energize the line.

3. SSM Sk. Fitter / S Sk. Fitter:


 In case of replacement of CT / PT, Sk. Fitter / S Sk. Fitter to:
 Open and close back plates
 Open wiring and replace existing CT / PT
 Adjust cable (if required)
 In case of cleaning of carbonizing of HT busbar, Sk. Fitter / S Sk. Fitter to:
 Open HT Switches back plates.
 Disconnect all HT Bus bars.
 Clean carbonized HT bus bars.
 Before reinstallation of HT Busbars also clean and replace damaged shrouds / supporters.
 All C.T / P.T of switchgear and trolley contacts to be checked and cleaned.
 Install back plates / side plates.
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4. SSM Karkun:
 Assist the Sk. Fitter / S Sk. Fitter.
 Should not perform work without instruction of SSM site supervisor, Sk. Fitter or S Sk. Fitter.

5. AM – SSM & AE -SSM


 AM to prepare debit note(s) and gate pass.

6. A.E /A.M /Manager--- SSM


 AM / Manager will Sign on debit note and gate pass while AE can sign on gate passes only.
 Managers will acquisition and allocation of materials to gang.

7. Manager – SSM:
 Sign on debit note and gate pass.

8. GM – HT:

 GM – HT to oversight all above mentioned activities and fulfill requirement of tools,


equipment, PPEs, SPEs and logistics for field staff along with material management.
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PROCESS FLOWS / PROCEDURE:

Gang reached site with tools, PPEs, SPEs and logistics

On-site TBT conducted at site

Written clearance given to SSM site supervisor who verifies shutdown

Gang starts work

Is job for CT / Yes


PT cleaning?
Open back plates

Open wiring and replace existing CT / PT

No
Adjust cable (if required)

Close back plates

Is job for Yes Open HT Switches back plates and


cleaning HT
busbars?
disconnect all HT Bus bars.

Clean carbonized HT bus bars


No

Replace damaged shrouds


and supporters

C.T / P.T of switchgear and trolley


contacts to be checked and cleaned

Install back plates / side plates

Give clearance to AOC

Remove short & ground from all sides by AOC

Energize the line END


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PERFORMANCE MANAGEMENT (TATs):


 TAT for CT / PT Replacement = 3 hours
 TAT for Cleaning of HT Busbars = 4Hrs , If Shrouds , supporting insulator work involved = up to 6
hours .
Time taken to complete task to be recorded as per form A.

TOOLS, EQUIPMENT& LOGISTICS:


Tools & Equipment:

a) Cutting Pliers (insulated)


b) Screw Driver (insulated handle)
c) Spanner Set (12 pieces)
d) Socket wrench set
e) Hacksaw Blade (with insulated frame)
f) Tool bag
g) Other necessary tools
PPEs & SPEs for Field Staff:
Before starting any work at site, Personal Protective Equipment and Special tools related to workshall be
checked comprehensively by concerned deputed staff. Some Tools normally used are listed below:-
a) Uniform
b) Safety shoes
c) Helmet with chin strip
d) Rubber and leather gloves
e) Live line tester
f) Danger sign board (safety tape) for placing at road
g) Emergency light (depending upon time of day)
h) Rain coats &gum boots (depending upon weather)

Logistics:
Truck will be required. All vehicles should pass the fitness criteria as per KESC fleet workshop:

GANG FORMATION &COMPETENCY:


Gang to be formed with respect to assigned KESC designations as stated below:

 01 Supervisor (A.E, EMO, Sub Engineer)


 01 Fitter
 01 Semi Skilled Fitter
 02 Karkuns

MATERIAL MANAGEMENT:
CT and PT:

 Maintain inventory record of CT and PT at SSM store and update movement, usage and record.
 Analyze usage of CT and PT and identify critical items.
 Track issuance, usage and receiving of material
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Chapter 3 - Replacement of RMU


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OBJECTIVE:
To assure “Replacement of RMU” on 11 KV network distribution in line with all safety policies and
procedures.

SCOPE:
This SOP shall apply to all SSM (KESC and 3rd party) employees working on replacement of RMU.

ROLES & RESPONSIBILITIES:


1. SSM Site Supervisor:
 Take confirmation of shutdown and isolation from AOC supervisor.
 Supervise all activities at site and implement all safety procedures at site including TBT
procedure (SP-010), Circulars 16, Circular 29 and Line Isolation SOP.
 Check license and certification of MTL driver, truck driver and crane operator.
 Before energization of newly installed RMU, SSM site supervisor to ensure the following:
 All covers are fixed
 RMU body is earthed
 After completion of work, give clearance to AOC supervisor.

2. AOC Supervisor:
 Before starting of work, give shutdown from HT side and short & ground as per Line Isolation
SOP.
 After completion of work, remove all short and grounds from HT side.
 Energize the line.

3. UGM Jointer Gang:


 Disconnect and reconnect HT terminations from all sides of RMU.
 Use termination kit if required before reconnection of HT terminations.
 Fix the Boots of RMU on all bushing

4. SSM Sk. Fitter / S Sk. Fitter:


 Replace existing RMU with new one by the help of crane / loader.
 Disconnect and reconnect earth wire from RMU.
 Fix the RMU covers properly.

5. SSM Karkun:
 Assist the Sk. Fitter / S Sk. Fitter.

6. AM – SSM & AE -SSM


 AM to prepare debit note(s) and gate pass While AE can make gate passes only.
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7 A.E /A.M /Manager--- SSM


 AM / Manager will Sign on debit note and gate pass while AE can sign on gate passes only..
 Managers will acquisition and allocation of materials to gang.

8.GM – HT:
 GM – HT to oversight all above mentioned activities and fulfill requirement of tools, equipment,
PPEs, SPEs and logistics for field staff along with material management.Should not perform
work without instruction of SSM site supervisor, Sk. Fitter or S Sk. Fitter.
PROCESS FLOWS / PROCEDURE:

Gang reached site with tools, PPEs, SPEs and logistics

On-site TBT conducted at site

Written clearance given to SSM site supervisor who verifies shutdown

Disconnect HT termination of RMU from all sides and disconnect earth wire

Replace RMU through crane

Reconnect HT termination at RMU from all sides and reconnect earth wire

Fix the boot with all bushing properly

Fix all the covers

Give clearance to AOC

Remove short & ground from all sides

Energize the line END


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PERFORMANCE MANAGEMENT (TATs):


TAT for RMU replacement = 5 hours
Time taken to complete task to be recorded as per form A.

TOOLS, EQUIPMENT & LOGISTICS:


Tools & Equipment:
a) Cutting Pliers (insulated)
b) Screw Driver (insulated handle)
c) Spanner Set (12 pieces)
d) Socket wrench set
e) Hacksaw Blade (with insulated frame)
f) Tool bag
g) Other necessary tools

PPEs & SPEs for Field Staff:


Before starting any work at site, Personal Protective Equipment and Special tools related to work shall be
checked comprehensively by concerned deputed staff. Some Tools normally used are listed below:-
a) Uniform
b) Safety shoes
c) Helmet with chin strip
d) Rubber and leather gloves
e) Live line tester
f) Danger sign board (safety tape) for placing at road
g) Emergency light (depending upon time of day)
h) Rain coats & gum boots (depending upon weather)

Logistics:
Following vehicles will be required. All vehicles should pass the fitness criteria as per KESC fleet workshop:
 MTL
 Truck
 Crane / Loader

GANG FORMATION &COMPETENCY:


Gang to be formed with respect to assigned KESC designations as stated below:
a) 01 Supervisor (A.E, EMO, Sub Engineer)
b) 01 Fitter
c) 01 Semi Skilled Fitter
d) 02 Karkuns

MATERIAL MANAGEMENT:
RMU:
 Maintain inventory record of RMU at SSM store and update movement, usage and record.
 Analyze usage of RMU and state requirement.
 Track issuance, usage and receiving of material
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Chapter 4 - Forwarding Job to SSM


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OBJECTIVE:
The purpose of this procedure is to ensure effective coordination among 118, Operations & SSM while
forwarding job to SSM.

ROLES & RESPONSIBILITIES:


1. In-Charge 118:
 Forward complaint from 118 to concerned IBC.

2. Manager Network:
 Manager Network to forward complaint to HT OPN.

3. Control Engineer:
 Control Engineer HT OPN to forward complaint of faulty transformer to DGM SSM/Control
Room SSM

4. DGM SSM:
 DGM SSM to request commercial clearance from IBC and approval from DCDO
 DGM SSM to forward job to SSM control for replacement. of transformer

5. DGM Network:
 DGM Network to give commercial clearance to DGM SSM / HT OPN Control after fulfilling the
following as and when needed:
a) Billing clearance from RPR
b) Written Undertaking from Consumer
c) Approval from DCDO

6. Dispatch Supervisor:
 Dispatch supervisor to ensure that gang is dispatched with tools, PPEs, SPEs and logistics after
conducting TBT.

SSM Control:
SSM Control to fill shut down form ( B-Form ) which is signed by Manager SSM and submitted to HT OPN
control while in odd hours AM / AE can also signed .

HT OPN Control:
HT OPN control gives receiving copy of form back to SSM control and informs HT AOC.

1. HT AOC Supervisor:
 Give shutdown from HT side and supervisor from IBC to give isolation from LT as per Line
Isolation SOP.
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2. SSM Site Supervisor:


 Take confirmation of shutdown and isolation (HT and LT) from AOC and LT supervisors.
 Supervise all SSM activities at site and implement all safety procedures including TBT procedure
(SP-010), Circulars 16, Circular 29 and Line Isolation SOP.

3. GM – HT:
 GM – HT to manage all above mentioned activities.

PROCESS FLOWS / PROCEDURE:

Consumer complaint registered in 118

Forwarded to concerned IBC

Does fault
Yes
pertain to Fault rectified by IBC
IBC?

END
No

Fault forwarded to HT OPN Control

Does fault No
pertain to Fault rectified by other department
SSM?

END
Yes
HT OPN control forwards fault to SSM control

SSM to request clearance from IBC

SSM control fills B-Form and requests for HT shutdown from HT OPN control

HT OPN control gives receiving copy of form back to SSM control and informs HT AOC
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SSM control will give shutdown form to SSM site supervisor

TBT conducted at SSM centre and gang dispatched with necessary tools, PPEs, SPEs and logistics

SSM site supervisor will present copy of form to AOC and request for shutdown arrangement

HT AOC will dispatch gang after conducting TBT at centre

AOC site supervisor will arrange HT shutdown as per Line Isolation SOP after conducting on-site TBT

Is LT
Yes
isolation Contact IBC and verbally
required? ask for shutdown

Yes
IBC to isolate all LT sides
as per Line Isolation SOP
No after conducting TBT at
centre and site

Gang starts work

PERFORMANCE MANAGEMENT:
 TAT for Forwarding job to SSM till shutdown: 30 minutes
 Time taken to complete task to be recorded as per form A
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Chapter 5 - Installation of 11kV Switches and Isolators or


Replacement of Trolley
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OBJECTIVE:
To replace one or more of the following in substations on 11 KV network distribution in line with all safety
policies and procedures:
 11kV switches and isolators
 Trolleys (OCB/VCB)

SCOPE:
This procedure shall apply to all SSM (KESC and 3rd party) employees working on Installation of 11kV
Switches and Isolators or Replacement of Trolley in substation.

ROLES & RESPONSIBILITIES:


1. SSM Site Supervisor:
 Take confirmation of shutdown and isolation (HT and LT) from AOC supervisor.
 Supervise all activities at site and implement all safety procedures including TBT procedure (SP-
010), Circulars 16, Circular 29 and Line Isolation SOP.
 Check license and certification of truck driver and crane operator.
 Before energization of newly installed switch, isolator or trolley, ensure the following:
 Back plates and side plates are installed.
 Existing panel is earthed.
 After completion of work, the SSM Control will give clearance to Operation Control
Engineer .

2. AOC Supervisor:
 Before starting of work, give shutdown from HT side and short & ground as per Line Isolation
SOP.
 Short and ground transformer HT bushing.
 After completion of work, remove all short and grounds.
 Energize the line.

3. UGM Jointer Gang:


 Disconnect and reconnect HT cable terminations from switch.
 Use termination kit if required before reconnection of HT cable terminations.

4. SSM Sk. Fitter / S Sk. Fitter:


 In case of installation of 11kV breaker and isolator:
 Place the switch / isolator accordance to 11 kV bus bar arrangement of existing panel.
 Couple newly installed switch / isolator with exiting panel through HT bus bar.
 Tighten busbar connections.
 Install back plates / side plates (if removed from Panel).
 In case of replacement of trolley (OCB / VCB):
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 Rack out faulty trolley from OCB/VCB.


 Place new trolley with help of crane / loader in substation.
 Rack-in new trolley in OCB/VCB.
 Install back plates / side plates (if removed from panel).

5. SSM Karkun:
 Assist the Sk. Fitter / S Sk. Fitter.
 Should not perform work without instruction of SSM site supervisor, Sk. Fitter or S Sk. Fitter.

6. AM – SSM & AE -SSM


 AM to prepare debit note(s) and gate pass While AE can make gate passes only.

8.A.E /A.M /Manager--- SSM


 AM / Manager will Sign on debit note and gate pass while AE can sign on gate passes only..
 Managers will acquisition and allocation of materials to gang.

9.GM – HT:
GM – HT to oversight all above mentioned activities and fulfill requirement of tools, equipment,
PPEs, SPEs and logistics for field staff along with material management.
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PROCESS FLOWS / PROCEDURE:


Gang reach at site with tools, PPEs,
SPE & logistics

On site TBT conducted at site

Written clearance given to SSM site


supervisor who verifies shutdown

Gang starts work

Yes
Is job for breaker
or isolator Disconnect HT cable terminations from switch
installation?
Place the switch / isolator accordance to 11 kV bus bar
arrangement of existing panel

No
Couple newly installed switch / isolator with exiting panel through HT busbar.

Tighten busbar connections and reconnect HT cable terminations from switch

Is job for trolley


Install back plates / side plates
replacement?

Yes
Rack out faulty trolley from OCB/VCB

Place new trolley with help of crane / loader in substation

No Rack-in new trolley and Install back plates / side plates

Give clearance to AOC

Remove short & ground Energize the line End


from all sides by AOC
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PERFORMANCE MANAGEMENT:
 TAT for installation of 11kV switches and isolators: 6 hours
 TAT for replacement of trolley: 2 hours
Time taken to complete task shall be recorded as per Annexure A

TOOLS, EQUIPMENT& LOGISTICS:


Tools & Equipment:
a) Cutting Pliers (insulated) g) Megger
b) Screw Driver (insulated handle) h) Punch Machine
c) Spanner Set (12 pieces) i) Steel/Iron Brush.
d) Socket wrench set j) Wooden slabs / slipper
e) Hacksaw Blade (with insulated frame) k) Iron rod (Lever)
f) Tool bag l) Other necessary tools

PPEs & SPEs for Field Staff:


Before starting any work at site, Personal Protective Equipment and Special tools related to work shall be
checked comprehensively by concerned deputed staff. Some Tools normally used are listed below:-
a) Uniform
b) Safety shoes
c) Helmet with chin strip
d) Rubber and leather gloves
e) Live line tester
f) Danger sign board (safety tape) for placing at road
g) Emergency light (depending upon time of day)
h) Rain coats &gum boots (depending upon weather)

Logistics:
Crane / Loader & Truck will be required. All vehicles should pass the fitness criteria as per KESC fleet
workshop:

GANG FORMATION:
Gang to be formed with respect to assigned KESC designations as stated below:
a) 01 Supervisor (A.E, EMO, Sub Engineer) c) 01 Semi Skilled Fitter
b) 01 Fitter d) 02 Karkuns

MATERIAL MANAGEMENT:
Switches and Isolators:
 Maintain inventory record of trolleys, switches and isolators at SSM store and update movement, usage
and record.
 Analyze usage of trolleys, switches and isolators. Identify critical makes of trolleys, switches and
isolators and state requirement of critical items.
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Chapter 6 - Replacement of LT Leads of Transformer to LT


Panel, LT Bus bars, HRC Fuses, Bases and Outgoing LT
Cable Termination in Substation
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OBJECTIVE:
To replace one or more of the following in substations on 11 KV network distribution:

 LT Leads of Transformers to LT Panel


 LT Busbar panels
 HRC Fuses and Bases
 Outgoing LT cable termination

SCOPE:
This SOP shall apply to all SSM (KESC and 3rd party) employees working on replacement of LT leads of
transformer to LT panel, LT busbar, HRC Fuses and Bases and outgoing cable termination in substation.

ROLES & RESPONSIBILITIES:


1. SSM Site Supervisor:
 Take confirmation of shutdown and isolation (HT and LT) from AOC and LT supervisors.
 Supervise all SSM activities at site and implement all safety procedures including TBT
procedure (SP-010), Circulars 16, Circular 29 and Line Isolation SOP.
 Check license and certification of truck driver.
 Before energization of newly installed leads, LT busbar, HRC Fuses, Bases and outgoing cable
termination, ensure the following:
 LT Leads and outgoing LT cable terminations are connected properly
 Phase sequence of LT leads.
 No of leads are provided as per transformer capacity.
 After completion of work, give clearance to AOC supervisor.

2. AOC Supervisor:
 Before starting of work, give shutdown from HT side and short & ground as per Line Isolation
SOP.
 Short and ground transformer HT bushing.
 Remove and place HRC fuses in LT panels.
 After completion of work, remove all short and grounds.
 Energize the line.

3. IBC Supervisor:
 Isolate LT and short and ground all sides.

4. SSM Sk. Fitter / S Sk. Fitter:


 In case of replacement of LT leads from transformer to LT panel, Sk. Fitter / S Sk. Fitter to:
 Short and ground LT busbar before starting work.
 Disconnect and reconnect LT leads from Transformer LT bushings and LT panel.
 In case of replacement of LT busbar, Sk. Fitter / S Sk. Fitter to:
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 Remove and reinstall HRC bases from panel.


 Remove and replace LT Busbars from LT panel.

5. UGM Jointer Gang:


 Disconnect and connect LT cable termination from LT panels.

6. SSM Karkun:
 Assist the Sk. Fitter / S Sk. Fitter.

7. AM – SSM & AE -SSM


 AM to prepare debit note(s) and gate pass While AE can make gate passes only.

8. A.E /A.M /Manager--- SSM


 AM / Manager will Sign on debit note and gate pass while AE can sign on gate passes only..
 Managers will acquisition and allocation of materials to gang.

9. GM – HT:
 GM – HT to oversight all above mentioned activities and fulfill requirement of tools,
equipment, PPEs, SPEs and logistics for field staff along with material management.
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PROCESS FLOWS / PROCEDURE:

Gang reached site with tools,


PPEs, SPEs and logistics

On-site TBT

Written Clearance given to SSM


site supervisor who verifies
shutdown

Short and ground LT panels and


gang starts work

Is job for LT leads Yes Short and ground LT


replacement? busbar

Disconnect and reconnect


No LT leads from Transformer
LT bushings and LT panel

Is job for LT
busbar panels’ Yes
replacement? Remove HRC bases from panel
and LT busbars from LT panel

Reinstall LT busbars at LT
panel and HRC bases
Give clearance to AOC

Remove short & ground Energize the line


from all sides
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PERFORMANCE MANAGEMENT (TATs):


TAT for replacement of LT leads of transformer to LT panel: 2 to 4 hours
TAT for replacement of LT bus bar: 6 hours
TAT for replacement of LT HRC bases & fuses:
TAT for replacement of LT outgoing LT termination:
Time taken to complete task to be recorded as per Annexure A.

TOOLS, EQUIPMENT& LOGISTICS:


Tools & Equipment:
a) Cutting Pliers (insulated) g) Megger
b) Screw Driver (insulated handle) h) Punch Machine
c) Spanner Set (12 pieces) i) Steel/Iron Brush.
d) Socket wrench set j) Wooden slabs / slipper
e) Hacksaw Blade (with insulated frame) k) Iron rod (Lever)
f) Tool bag l) Other necessary tools

PPEs & SPEs for Field Staff:


Before starting any work at site, Personal Protective Equipment and Special tools related to workshall be
checked comprehensively by concerned deputed staff. Some Tools normally used are listed below:-
a) Uniform
b) Safety shoes
c) Helmet with chin strip
d) Rubber and leather gloves
e) Live line tester
f) Danger sign board (safety tape) for placing at road
g) Emergency light (depending upon time of day)
h) Rain coats &gum boots (depending upon weather)

Logistics:
Truck will be required. All vehicles should pass the fitness criteria as per KESC fleet workshop:

GANG FORMATION &COMPETENCY:


Gang to be formed with respect to assigned KESC designations as stated below:
a) 01 Supervisor (A.E, EMO, Sub Engineer)
b) 01 Fitter
c) 01 Semi Skilled Fitter
d) 02 Karkuns

MATERIAL MANAGEMENT:
LT Leads, HRC Fuses, Bases & LT busbar:
 Maintain inventory record of LT Leads, HRC Fuses, Bases and LT busbar at SSM store and update
movement, usage and record.
 Analyze usage of LT Leads, HRC Fuses, Bases and LT busbar.
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Chapter 7- Installation of New PMT


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OBJECTIVE:
To assure “Installation of New PMT” on 11 KV network distribution in line with all safety policies and
procedures.

SCOPE:
This SOP shall apply to all SSM (KESC and 3rd party) employees working on installation of new PMT.

ROLES & RESPONSIBILITIES:


1. SSM Site Supervisor:
 Take confirmation of shutdown and isolation (HT and LT) from AOC and LT supervisors.
 Supervise all activities at site and implement safety procedures including TBT procedure (SP-
010), Circulars 16, Circular 29 and Line Isolation SOP.
 Check license and certification of MTL driver, truck driver and crane operator.
 Before energization of newly installed transformer, ensure the following:
 Leads are connected properly
 Oil level and silica gel of new transformer is satisfactory
 Phase sequence of LT
 Neutral lead and transformer body earth is connected
 Pole structure properly earthed
 After completion of work, give clearance to AOC supervisor.

2. LT Supervisor:
 Before starting of work, give isolation from LT side and short & ground all sides as per Line
Isolation SOP.
 After completion of work, remove all short and grounds from LT side.
 Give clearance to AOC supervisor from LT side.

3. AOC Supervisor:
 Before starting of work, give shutdown from HT side and short & ground all sides as per Line
Isolation SOP.
 After receiving clearance from SSM site supervisor, remove all short and ground from HT side.
 Energize the line and put LT breaker ON.

4. SSM Sk. Fitter / S Sk. Fitter:


 Sk. Fitter / S Sk. Fitter to:
 Fix all 3 No’s. D/O cut out on channel bracket
 Place the new PMT on structure
 Connect cambric leads from DO cutout to PMT HT bushing
 Connect DO cutout to overhead HT busbar
 Install LT breaker & DB
 Connect LT leads on PMT bushing to LT breaker and LT breaker to DB
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5. SSM Karkun:
 Assist the Sk. Fitter / S Sk. Fitter.
 Should not perform work without instruction of SSM site supervisor, Sk. Fitter or S Sk. Fitter
(team in-charge).

6. AM – SSM & AE -SSM


 AM to prepare debit note(s) and gate pass While AE can make gate passes only.

7. A.E /A.M /Manager--- SSM


 AM / Manager will Sign on debit note and gate pass while AE can sign on gate passes only..
 Managers will acquisition and allocation of materials to gang.

8. GM – HT:
 GM – HT to oversight all above mentioned activities and fulfill requirement of tools, equipment,
PPEs, SPEs and logistics for field staff along with material management.
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PROCESS FLOWS / PROCEDURE:

Gang reached site with tools,


PPEs, SPEs and logistics

On-site TBT

Written Clearance given to SSM


site supervisor who verifies
shutdown

PMT NO Make Temporary


structure
arrangement
available

Yes

Job started

Checking of oil level, oil


leakage and condition of
silica gel of new
transformer

Placing of new transformer


through crane

Install DO cutout, LT breaker


and DB

Connection of HT and LT
leads

Give Clearance to AOC

Remove short & ground from Energize Line & put


all sides (HT & LT) by AOC LT breaker ON
from HT and IBC from LT
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PERFORMANCE MANAGEMENT:
 TAT for Installation of new PMT is 6 hours.
 Time taken to complete task to be recorded as per form A.

TOOLS, EQUIPMENT& LOGISTICS:


Tools & Equipment:
a) Cutting Pliers (insulated)
b) Screw Driver (insulated handle)
c) Spanner Set (12 pieces)
d) Socket wrench set
e) Hacksaw Blade (with insulated frame)
f) Tool bag
g) Other necessary tools

PPEs & SPEs for Field Staff:


Before starting any work at site, Personal Protective Equipment and Special tools related to work shall be
checked comprehensively by concerned deputed staff. Some Tools normally used are listed below:-
a) Uniform
b) Safety shoes
c) Helmet with chin strip
d) Rubber and leather gloves
e) Live line tester
f) Full body harness with front position belt
g) Danger sign board (safety tape) for placing at road
h) Emergency light (depending upon time of day)
i) Rain coats & gum boots (depending upon weather)

Logistics:
MTL, Crane / Loader and Truck will be required. All vehicles should pass the fitness criteria as per KESC
fleet workshop:

GANG FORMATION &COMPETENCY:


Gang to be formed with respect to assigned KESC designations as stated below:
e) 01 Supervisor (A.E, EMO, Sub Engineer)
f) 01 Fitter
g) 01 Semi Skilled Fitter
h) 02 Karkuns

MATERIAL MANAGEMENT:
New PMT, DO cutout, LT Breaker and DB:
 Maintain inventory record of New PMT, DO cutout, LT Breaker and DB at SSM store and update
movement, usage and record.
 Analyze usage of New PMT, DO cutout, LT Breaker and DB and identify critical items.
 Track issuance, usage and receiving of material.
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Chapter 8 - Master Key Handling of Substation


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OBJECTIVE:
To state “Master Key Handling of Substation” on 11 KV network distribution.

SCOPE:
This SOP shall apply to the following H.T sections:

 Operation
 SSM
 UGM

ROLES & RESPONSIBILITIES:

Operation Section:
 At each Operation center 04 Master Keys must be issued.
a) One Key for each Supervisor with the site Operation gang (Two gangs at a time)
b) One with dispatched Supervisor of the Operation center.
c) One spare Master Key at each Operation center for emergency use.

SSM Section:
 04 Master Keys to be issued to each SSM section
a) One Key for each Fitter / Supervisor to be dispatched with team (Two teams at a time)
b) One with dispatch Supervisor of the Control room for emergency use.
c) One Key in Manager Custody for site inspection use.

UGM Section:
 05 Master Keys to be issued to each UGM section

a) One Key for each Testing team (Three teams at a time)


b) One with dispatch supervisor of the control room for emergency use.
c) One Key in Manager’s custody for site inspections / emergency use.

Dispatch supervisors of all 03 sections:


 Issue Master keys to supervisors on daily basis after making its entry in Master Key logbook with time,
date and signatures of both gang supervisors and dispatch supervisor.

1. Gang supervisors:
 On reporting back to the center will deposit the Master Keys to the dispatch supervisor
available in control room and also be recorded in the Master Key logbook with time, date and
signatures of both gang & dispatch supervisors.
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2. Control In-Charge:
 One wooden box with glass top to be fixed in each control room and its main key must be with
control in-charge available on duty. Emergency use key must be used in emergency only.

3. Billing Managers / AMs:


 In Industrial areas, Billing Managers / AM and new connection department responsible have
the Master Keys may be allowed to keep OR contact Manager Operation for issuance of key &
later to be deposited back on daily basis making proper entries in key Management Log Book.

4. DGM & GM:


 GM and DGM will collect / deposit Master Key from control room by making entry in Key
Management Log Book with time, date and signatures.
 GM and DGM to oversight all above mentioned activities.

5. Security Department:
 Carry out surprise visits of substations.
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Chapter 9 - Diesel Generators


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OBJECTIVE:
To state methodology of providing “Diesel Generators” to consumers for stand-by purposes.

SCOPE:
This SOP shall apply to all SSM (KESC and 3rd party) employees working on managing of diesel generators
for stand-by purposes.

ROLES & RESPONSIBILITIES:


1. Consumer:
 Send request for generator to CEO, CDO and DCDO.
 Submit paid copy of estimate to IBC for confirmation of payment.

2. DCDCO:
 Decide whether payment required or not.
 Forward to GM – HT.

3. GM – HT:
 After receiving approval from DCDO, forward request to DGM – SSM for costing.
 After receiving payment confirmation from GM – IBC, forward request of consumer to GM –
IBC and DGM – SSM.

4. DGM – SSM:
 Estimate costing and forward to GM – IBC.
 After receiving final decision from GM – HT, instruct Manager – SSM to make arrangements.

5. Manager – SSM:
 Make arrangements for diesel generator and dispatch it along with operator.
 Intimate to GM – HT about safe installation of equipment.
 Before dispatching generator, ensure availability of diesel.
 Ensure maintenance of generator as described in Routine Maintenance.

6. GM – IBC:
 Forward costing to DGM – Network for issuance of estimate.
 After receiving payment confirmation from DGM – Network, forward to GM – HT.
 Instruct DGM – Network for providing changeover with leads and gang.

7. DGM – Network:
 Issue estimate to consumer.
 Receive copy of payment slip.
 Forward payment confirmation to GM – IBC.
 Instruct Manager – Network to arrange changeover.
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8. Manager Network:
 Dispatch changeover to site with gang with all accessories.

9. Generator Operator:
 Make all arrangements as described by Manager – SSM.
 Before dispatch, ensure generator is working.
 Check fuel position.
 Responsible for putting generator ON / OFF.
 After installation, test generator before event starts.

10. IBC gang:


 Connect leads with generator.
 Connect changeover and DB.
 Verify from consumer side.
 Before start of event, check changeover by putting load.

ROUTINE MAINTENANCE:
Daily Maintenance Plan:

The generator will be checked daily for water and fuel before starting and ensure that all the wires are
tightly connected and there is no leakage of grease, oil etc

Weekly Maintenance Plan:

Ensure that air filter is clean, battery is charged and oil level is maintained to required level.

Monthly Maintenance Plan:

The generator will be checked monthly for oil and oil filter. If required, then oil filter to be changed. Besides
this, the generator should be cleaned monthly.
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PROCESS FLOWS / PROCEDURE:

Request from consumer to CEO, CDO and DCDO

Is payment Yes
Forwarded to SSM for costing
required?

Forwarded to IBC for issuing


cost to consumer
No

Confirmation of payment

Forwarded to SSM for installation of generator

Generator, leads, changeover, IBC and SSM gangs


dispatched to site

Information given to hire ups after installation

END
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Chapter 10 - Replacement of Transformer


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OBJECTIVE:
To assure “Replacement of Transformer (PMT/SS)” on 11 KV network distribution in line with all safety
policies and procedures.

SCOPE:
This SOP shall apply to all SSM (KESC and 3rd party) employees working on replacement of distribution
transformer.

ROLES & RESPONSIBILITIES:


1. SSM Site Supervisor:
 Take confirmation of shutdown and isolation (HT and LT) from AOC and LT supervisors.
 Supervise all activities at site and implement all safety procedures including TBT procedure (SP-
010), Circulars 16, Circular 29 and Line Isolation SOP.
 Check license and certification of MTL driver, truck driver and crane operator.
 Before energization of newly installed transformer, ensure the following:
 Leads are connected properly
 Oil level and silica gel of new transformer is satisfactory
 Phase sequence of LT
 Neutral lead and transformer body earth is connected
 Pole structure properly earthed
 After completion of work, give clearance to AOC supervisor.

2. LT Supervisor:
 Before starting of work, give isolation from LT side and short & ground all sides as per Line
Isolation SOP.
 After completion of work, remove all short and grounds from LT side.
 Give clearance to AOC supervisor from LT side.

3. AOC Supervisor:
 Before starting of work, give shutdown from HT side and short & ground all sides as per Line
Isolation SOP.
 After receiving clearance from SSM site supervisor, remove all short and ground from HT side.
 Energize the line and put LT breaker ON.

4. SSM Sk. Fitter / S Sk. Fitter:


 Disconnect and connect cambric HT leads from transformer HT bushing.
 Disconnect and connect LT leads from transformer LT bushing.
 Remove existing and place new transformer on structure or in substation through crane.

5. SSM Karkun:
 Assist the Sk. Fitter / S Sk. Fitter.
 Should not perform work without instruction of SSM site supervisor, Sk. Fitter or S Sk. Fitter
(team in-charge).
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6. AM – SSM & AE -SSM


 AM to prepare debit note(s) and gate pass While AE can make gate passes only.

7. A.E /A.M /Manager--- SSM


 AM / Manager will Sign on debit note and gate pass while AE can sign on gate passes only..
 Managers will acquisition and allocation of materials to gang.

8. GM – HT:
GM – HT to oversight all above mentioned activities and fulfill requirement of tools, equipment,
PPEs, SPEs and logistics for field staff along with material management.
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PROCESS FLOWS / PROCEDURE:

Gang reached site with tools, PPEs, SPEs and logistics

On-site TBT conducted at site

Written clearance given to SSM site supervisor who verifies shutdown

Is PMT platform No
available or work is in Make temporary arrangement
S/S?

Yes

Gang starts work

Disconnection and removal of HT and LT leads from transformer bushings

Removal of existing transformer through crane

Checking of oil level, oil leakage and condition of silica gel of new transformer

Placing of new transformer through crane

Connection of HT and LT leads

Give clearance to AOC

Remove short & ground from all sides (HT & LT) by AOC from HT and IBC from LT

Energize the line

Put LT breaker ON

END
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PERFORMANCE MANAGEMENT (TATs):


TAT for transformer replacement = 4 hours (After getting Shut-Down)
Time taken to complete task to be recorded as per form A.
Performance of SSM and TSW to be measured with Form B & C on Annexure respectively.

TOOLS, EQUIPMENT& LOGISTICS:


Tools & Equipment:

a) Cutting Pliers (insulated) e) Hacksaw Blade (with insulated frame)


b) Screw Driver (insulated handle) f) Tool bag
c) Spanner Set (12 pieces) g) Other necessary tools
d) Socket wrench set

PPEs & SPEs for Field Staff:


Before starting any work at site, Personal Protective Equipment and Special tools related to work shall be
checked comprehensively by concerned deputed staff. Some tools normally used are listed below:-

 Uniform
 Safety shoes
 Helmet with chin strip
 Rubber and leather gloves
 Live line tester
 Full body harness with front position belt
 Danger sign board (safety tape) for placing at road
 Emergency light (depending upon time of day)
 Rain coats & gum boots (depending upon weather)
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Logistics:
MTL, Truck, Crane / Loader will be required. All vehicles should pass fitness criteria as per KESC fleet
workshop:

GANG FORMATION &COMPETENCY:

Gang to be formed with respect to assigned KESC designations as stated below:


a) 01 Supervisor (A.E, EMO, Sub Engineer)
b) 01 Fitter
c) 01 Semi Skilled Fitter
d) 02 Karkuns

MATERIAL MANAGEMENT:

TRANSFORMER:
 Maintain inventory record of transformers at SSM store and update movement, usage and record.
 Analyze usage of transformers and identify critical ratings of transformers. State requirement of
critical transformers.
 Track issuance, usage and receiving of material.
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Chapter 11

Construction of New Substation


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Purpose:
The Policy is developed for the construction of new sizes of 11 KV substations in the KESC Distribution
network, due to induction of new size 11 KV VCB Panels & Standardization of Distribution Transformer
sizes

Scope:
This policy covers construction of new sizes 11 KV Sub Station in KESC- HT / LT Distribution network (All
regions). Four different sizes of 11 KV Substations are constructed in KESC Distribution network, which are
single room (HT Switch Room) & two rooms (HT & Trafo+LT Panel Room)

A) Single Room Sub-Station (HT Switch Room):

This type of substation shall be constructed for the applicants applied for 11 KV bulk supply or
for switching purpose of 11 KV feeders/network

Two different sizes of single room substation are designed i-e type “A” & type “B” as below. The
selection of the substation shall be as per site/plot condition or with the mutual agreement with
the applicant

i) HT Switch Room (Type- A):

Single room substation shall consist of maximum 04 Nos. of HT/MV Panels. Size of the
substation shall be 15 x 17 x 12, with placement of equipments as per attached drawing in
annex-A

ii) HT Switch Room (Type- B):

Single room substation shall consist of maximum 04 Nos. of HT/MV Panels. Size of the
substation shall be 16’ x 14’ x 12, with placement of equipments as per attached drawing in
annex-B

B) Two Rooms Sub-Station (11 KV Distribution Sub Station):

This type of substation shall be constructed for the applicants applied for more than 400 KW to
800 KW load & will be constructed in the premises of applicant

Two different sizes of two room substation are designed i-e type “A” & type “B” as below. The
selection of the substation shall be as per site/plot condition or with the mutual agreement with
the applicant

i) Two Room Substation (Type- A):

Two room substation shall designed as one room for HT/MV panel (max: 04 Nos.) & second
room for Distribution transformer & LT Panel. Size of the substation shall be 26’ x 17’x12’ feet.
The placement of HT/MV and LT equipments shall be as per Annex-C

ii) Two Room Substation (Type- B):

Two room substation shall designed as one room for HT/MV panel (max: 04 Nos.) & second
room for Distribution transformer & LT Panel. Size of the substation shall be 30’ x 15’x12’ feet.
The placement of HT/MV and LT equipments shall be as per Annex-D
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In case, the load of the applicant increases from 800 KW, than he shall provide/construct additional room
for transformer equal to the above specified size of transformer room.

Minimum clearances with equipments:


Clearance in front of switches – 4 ft minimum (2ft trolley distance and 2 ft working distance.
Minimum clearance distance between two transformers – 2 ft minimum
Front clearance of transformers (transformer side facing the door) – 3 ft minimum

Material / Equipments:
All equipments as MV panels/ Trafo:/LT panels/MV/LV cables and hardware material used in substation
shall be confirming to relevant (Amended up to date) KESC Standard Specifications. All materials shall be
tested/inspected as per self finance policy / SOP

Proper tagging on HT- switches & route of destination of in-comings, out-goings & local transformer
cables, long-with LT circuit destination should be clearly mentioned including network name with network
code, danger signs & emergency contact numbers of Sub-station on outside front wall.

Substation Location / Site Selection:


i. No any type of substation shall be allowed in the basement of any residential/commercial
building.
ii. Consumer shall provide the undertaking legal document as per attached Agreement/
undertaking format for ownership of Sub-Station.
iii. The substation shall be constructed preferably on main roads if not than at-least on 20 feet
wide road.
iv. There shall be provision of free movement of cranes & lifter for handling of the heavy
equipments placed inside the substation
v. The sub-station area should be free from the risk of sewerage/rain/flood and storm water
damages. The drain provided must be kept in working order by the owner/applicant
vi. Proper ventilation shall be provided in order to dissipate heat losses from the electrical
equipments (as per attached drawings)
vii. The personnel access to Sub-station must be easy/free movement
viii. The service such as drains, sewers, piping or wiring are not permitted to pass through the
sub-station area
ix. For HT/LT cables trenches shall be as per single HT Room & Two room Substation as per
Annexure A, B, C & D
x. Natural airflow directly from outside of the building is preferred, position of ventilator should
be such as to provide cross ventilation HT Panel, transformer and other equipments.
xi. In multistory building where roof height limited to 10’-0” will also be accepted as a special
case. Other requirements/ conditions shall remain same.

Construction Requirements:

i. Substation shall be constructed by the applicant under New Connection self finance policy
ii. The lay out plan & civil drawings shall be provided by the KESC (NC Department.) to applicant and
other utilities
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iii. Overall supervision shall be done by KESC & charges will be paid by the applicant as per NC policy
define charges when it is being constructed by applicant
iv. All the Electrical Equipments & Accessories in substation shall be installed by the applicant/KESC
approved contactor under the supervision of KESC for S.F Cases
v. Earthling shall be done by the applicant as per KESC Specification and the resistance shall be
measured/checked by the KESC officials. Annexure-E
vi. During construction of substation, applicant shall call the KESCs designated engineer(s) for inspection
at the different levels.
vii. After completion of civil works & installation of equipments, the substation shall handed over to KESC,
& become the KESC Property. (Agreement / Undertaking / Deed for Handing/ Taking over of Sub-
Station)

Provision of Fire Extinguisher


For each room of Sub Station one unit of fire extinguisher shall be provided/ installed by the applicant as
per below specification. This unit shall be used only for minor fire especially during and switching &
preventive maintenance:

 Type : CO2 Fire Extinguisher


 Capacity : 5 Kg
 Make : UK, USA or European origin only (Currently Gloria and Jockel brand are in KESC
use)
 Installation : One per room
 Location : Inside the room near door at the height of 4‘- 6”

Sub-Station Construction:
i. The sub-station is constructed on RCC framed structure. The structure is composed of beams &
column with the load being transferred into the beam via the floor and then down to foundation
through column & the walls are to be constructed by machine made blocks. The walls must have
sufficient strength to support the weight of any equipment mounted on it without collapsing

ii. The plinth level of substation shall be 3 feet from the road.
iii. The ceiling shall be of RCC Cement Concrete construction.
iv. The finish of internal wall and ceiling must be clean, smooth and must be painted (Approved by
Engineer) the floor must be impervious to any oil spillage from main transformer.
v. The sub-station floor, including trenches, conduits etc is to be formed in accordance with the position
and details shown on KESC drawing/specifications
vi. The floor must have a level steel trowelled finish
vii. If the sub-station floor is laid on natural or filled ground an appropriate waterproofing membrane is
to be placed between the underside of sub-station floor and the ground
viii. The sub-station shall be constructed using approved water proofing materials
ix. To protect the Sub-Station equipment expose to dampness / water throughout its life requires
proper site drainage and water proofing
x. Sub-station requires special attention to ventilation in order to dissipate heat losses from electrical
equipment wherever possible natural air flow to the outside of the building will be used
xi. Forced ventilation should be used where natural ventilation is not practicable. Forced ventilation by
mean of industrial fan (s) with timer switch must be designed, supplied and installed by the owner as
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per KESC’s requirements (The power supply to meter shall be on account of KESC) The air flow
through the ventilation will be checked by KESC before the final approval.
xii. The position of the vent must be directly to outside air, if this is not achievable then forced
ventilation is required
xiii. Provision must be made within the sub-station to contain any oil spillage (in the unlikely event of a
transformer tank failure) and slope to a common point
xiv. A buried earthing/ grounding system is necessary for sub-station and installed equipments, the
earthing system shall be provided as per KESC’s design/specification
xv. Trench shall be RCC with RCC covers; the trench cover when laid across the trench shall be flush with
the surrounding floor level
xvi. Antitheft door with louvers type should be provided as per KESC’s design. Annex-E
xvii. The owner will supply and install the light & power distribution board and the necessary light fittings
and power outlets in the sub-station including all wiring. KESC will connect the distribution board to
the supply point on the low voltage board.

Documentations (Agreement /Undertaking):


i. The agreement/ Undertaking shall draft as per Annexure “g” (appended below) on Rs. 100 Stamp
Paper and will be duly signed & stamped by concerned GM (NC) & GM (Operation) & 2nd Party
(Applicant).
ii. The Original Stamp paper (duly filled & stamped as per above) will be forwarded to KESC Share
department to kept in safe custody and two set of copies shall be forwarded to concerned GM
Operation & GM (NC) KESC for their record. A copy may also be provided to applicant, if required.
iii. The other required documentations or formalities other than agreement/undertaking shall be
fulfill/done as per existing NC practice/policy.
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Chapter –12 Re-Construction of New 11 KV Sub Station


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Objective:
The Policy is developed for the re-construction of 11 KV substations in the KESC Distribution network
which are in dilapidated condition.

Scope:
This policy covers re-construction of existing 11 KV substations on the same footprint includes the
dismantling of Equipments placed in a substation, demolition of existed civil structure, foundation,
superstructure, Finishing work, Completion and handing over to user for reinstallation of substation
equipments.

Roles & Responsibilities

 Substation Maintenance 11KV Network responsible to vacate substation on time for reconstruction.
After job completion electrical equipments/ accessories would be reinstalled with due safety
precautions.

 Works department responsible to supervise construction activities as per the standard procedure
and civil engineering practices.

 Third Party Contractor is responsible to execute and complete reconstruction of substation as per
the terms and conditions of contractual agreement.
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Process Flow and Procedure


Process Flow Procedure Action by
1. SSM conduct initial site survey to account for the 1. Manager SSM
SSM conduct site
survey
deteriorated condition of substation
2. Produce and process prescribed MRF form to 2. Manager SSM
explain the physical condition of substation with
Issue MRF form
due approval as per signatory mandate
for rehabilitation of 3. Finance and Business Administration (FBA) received
substation 3. Manager FBA
the approved MRF from along with pictorial
evidence from the user. Check and approve as per
FBA validate the
the availability of budget than proceed to Works
user requirement department 4. Manager Works
based on site
survey report than 4. Civil engineer accompanied with authorized regional
allocation of
budget
personnel visit the same facilitation centre assess
the physical condition of roof, floor, walls, columns
and beams, moreover observe the road level and 5. DGM Works
Works dept
Reconstruction/ surrounding circumstances.
conduct site
survey
Repair & Maint 5. Works department conclude and report the level of
rehabilitation/ reconstruction require as per the
Civil Engineering principle. 6. DGM Works
Estimated cost
6. Works determine the estimated cost to be required
GM HT & DCDO
approve the form issue by to complete the reconstruction job segregated in 7. DGM SSM
estimated cost of Works department
reconstruction accordance with the various levels of civil activities.
7. User department received back the case along with
detail inputs of all the concern departments. Now
Fixed Asset
requisition (FAR) the user provide Asset Under Construction form
form duly approve
by DCDO for AUC (AUC) as per the estimated cost provided by the
8. Manager FBA
account Works department
8. FBA receive AUC form with due approval as per
signatory mandate review the estimated cost
FBA allocate AUC
# as per provided by the Works department and available
budgetary
approval
approved budget than coordinate with C&A
(Controlling and Account) department to open an 9. Manager Works
AUC for proper capitalization
9. Works department get the AUC # prepare and issue 10. DGM PP
Works issue PR
on account of AUC Purchase Requisition (PR) send back to user for final
approval
10. Approved PR enclosed with relevant approved
Procurement dept
documents forwarded to Procurement department 11. DGM PP
select from the list for bidding and Contractual Agreement.
of pre-qualified
contractor via 11. Procurement department send copy of an 12. Manager
tendering process
agreement to Civil and user. Works
12. Works, Contractor, HSEQ and user has to plan joint
Prepare legal
agreement to be
site survey to ensure all the live equipments and
signed by accessories remove from substation (Refer 6.1 for
Contractor,
CDO,CFO, vacation of substation) 13. Manager
CSCO,CEO
13. SSM/ UGM/ Operation & IBC coordinate for removal SSM/UGM/
of Equipments and accessories installed inside Operation/ IBC
SSM Vacate Works dept issue SSM reinstall and Substation and give clearance to Works
Substation and
issue Safety
work order form
Contractor wise for
energize normal
system of S/S after department. (refer Annex “A” Vacation of Sub- 14. Contractor and
Clearance Site mobilization completion
station) Manager Works
14. Works department issue work order to Contractor
15. DGM/Manager
for commencement of reconstruction of Sub-station
SSM/UGM/
(refer Annex “B” Execution of Civil work)
Operation/ IBC
15. SSM, HT Operation, UGM and IBC coordinate to
reinstall all electrical equipments and accessories
inside substation
16.
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Vacation of Substation
Process Flow Procedure Action Taken by
1. SSM survey the substation site 1. Manager
and record number of SSM
equipments with their make
SSM Site survey
and capacity
2. Operation prepare temporary 2. Manager
shifting plan with single line Operation
Operation
temporary shifting
diagram in coordination with
plan with SLD SSM, UGM and IBC
3. Operation, SSM, UGM and IBC
3. DGM/SSM,
Operation, UGM,
workout material and
Operation,
SSM & IBC
material
overhead requirement
UGM & IBC
requirement
precisely to execute
temporary shifting of
Material issued via
substation equipments and
DTN from central
store
accessories
4. SSM compile consolidated
4. DGM SSM
material and overhead
requirement for approval as
IBC erect HT poles
for mounting PMT
per signatory mandate by
DDCO
5. Material to be issued via DTN
5. SSM, UGM,
from central store
Shutdown Operation &
SSM mount
UGM/ IBC shift 6. IBC erect HT poles for
alternate PMT
HT/ LT cables IBC
mounting alternate PMT than
communicate in writing about 6. Manager LT
Shutdown completion of job Network
Operation
normalize 7. SSM mount alternate PMT
temporary
arrangement with accessories 7. Manager
8. UGM/ IBC get shutdown for SSM
shifting of HT/ LT cables on
SSM dismantle SSM give 8. UGM/ IBC
transformer, clearance to works completion communicate to
switches with for start of Civil
accessories work SSM & Operation 9. Manager
9. Operation get shutdown to Operation
normalize the temporary
arrangement 10. Manager
10. SSM dismantle transformer, SSM
switches along with
accessories accordingly 11. DGM SSM
11. SSM give clearance to Works
department for
commencement of civil work
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Execution of Civil Works


Process Procedure Time Taken in Days

1. 1
1. Site Visit
Dismantling &
removal of debris
2. 3
2. Demolishing of Existing
Structure

3. Layout 3. 1

Foundation 4. Excavation 4. 1
5. 1
5. PCC (1:4:8)

6. Footing Pouring, Block 6. 3


Masonry upto Plinth
SuperStructure
7. Plinth and Beam 7. 5

8. Backfilling with soiling 8. 3


9. 2
9. PCC Floor

10. Trench Making 10. 8


Finish work

11. Block Masonry 11. 10

12. Column Pouring roof slab 12. 12

13. External Plaster 13. 5


Completion/
Handing over 14. 5
14. Internal Plaster
15. 1
15. Fixing of door
16. 2
16. Fixing of widows
17. 3
17. Paint works
18. 2
18. Electrification

19. Handing over to SSM


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Reinstallation of Equipments and Accessories


Process Flow Procedure Action Taken by

Works & SSM joint


survey on
1. SSM and Works department 1. Works
completion of Civil conduct joint survey after
work
completion

SSM acknowledge
and takeover
2. SSM representative acknowledge 2. DGM/Manager
substation
according to their requirement SSM
than take over newly constructed
substation premise
SSM install LT 3. Manager SSM
Panel frame
3. SSM first install LT Panel frame
4. Manager SSM

SSM install,
transformer, 4. SSM install transformer, switches 5. Manager SSM
switches with along with accessories refurbished
accessories
within due course of construction 6. Manager UGM/
IBC
5. SSM communicate clearance to
Shutdown
UGM & IBC Operation, UGM and IBC
reconnect HT/ LT
cable
6. UGM/ IBC get shutdown and plan 7. Manager
to reconnect the HT/ LT cables to Operation
substation than give clearance to
Operation 8. Manager SSM
normalize system Operation
through substation

7. Operation normalize the system


through substation 9. Manager SSM
Shutdown
SSM dismantle 8. SSM get shutdown and dismantle 10. Manager IBC
equipments and
accessories all the equipments and
accessories installed for
temporary arrangement
IBC remove HT
poles 9. SSM give clearance on completion
to Operation, UGM and IBC

10. IBC finally remove HT poles


accordingly
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Performance Management (TATs)


Contractor performance to be measured in accordance with the day wise schedule provided by Works
department (refers annexure 12.02).

Tools and Equipments


Contractor obligates to supply at its own cost following tools and equipment;

 Plants
 Tools and appliances
 Implements
 Ladders
 Cartage
 Tackles
 Scaffolding

Contractor may request the Company in writing to allow the Contractor to operate any available
equipment of the Company, for the performance of the works. Material/ equipments employed for the
purposes of dismantling and excavation in the course of carrying out the works shall be the Company’s
property and may only be disposed off as directed by the Company.

Training/ Competency
Contractor

The Contractor represents and warrants to the Company that the Contractor has a requisite experience
and skill is able and willing to carry out the Works and provide any related works/ services as required by
the Company in this regard in accordance with instructions/ technical parameter of the Company to the
entire satisfaction of the Company.

Works Department

Manager Works may conduct an orientation session for Contractor, to communicate the HSEQ policy of
the Company that obligate the contractor to provide sufficient PPEs to their work force during the course
of civil construction business on site.

Works department may also highlight about the electrical hazards that may be incurred during the process
of digging.

Safety
Contractor shall comply with all applicable Health, Safety, Environment and Quality (HSEQ) laws, rules,
orders and regulations during the execution and performance of works. Contractor shall immediately
remove and replace its personnel who violate the safety provision.

Contractor solely responsible for it employees, sub-contractors and equipment in case of any accident/
danger/ hazardous condition occurring on Site and the Contractor shall provide safety equipment
including without limitation Safety belt, helmets and shoes to all it personnel as well as signage, fencing,
lighting, guarding and barricades.
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Provision of Fire Extinguisher

i. For each room of Sub Station one unit of fire extinguisher shall be provided/ installed by the Civil
dept If Re- Constructed KESC as per below specification. This unit shall be used only for minor fire
especially during and switching & preventive maintenance.
 Type : CO2 Fire Extinguisher
 Capacity : 5 Kg
 Make : UK, USA or European origin only ( Currently Gloria and Jockel brand
are in KESC use )
 Installation : One per room
 Location : Inside the room near door at the height of 4 ‘- 6”.
ii. Easy access for personnel, vehicle and hoist equipment from the outside to ensure ease in
installation, maintenance and future replacement/retirement of transformer.

iii. Transformer and switch gear must be ventilated because they give off large quantities of heat.

iv. The forced ventilation system comprising fans, ducting and inlet/outlet vent must be designed,
supplied and installed by the owner. The air flow through the ventilation will be checked by KESC
before the final approval.
v. Antitheft door with louvers type should be provided as per KESC’s design.

vi. Transformer, switches and other accessories properly earth and ground as per the prevailing SOP

Material Management (issuance & return of material)


Contractor shall supply and arrange at its own cost all material s and equipment, including without
limitation plants, tools, appliances, implements, ladders, cartage, tackles, scaffolding and temporary works
required for the proper execution of the works whether original or substituted, regardless of whether or
not included in the specifications listed in the contract, and which are necessary for the successful
completion of works to the satisfaction of the Company.
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ABBREVIATION

GM - General Manager
DGM - Deputy General Manager
RMC - Regional Material Coordinator
IM - Inventory Management
PM - Preventive Maintenance
CM - Corrective Maintenance
HoD - Head of department
SSM - Sub Station Maintenance
D/O cut out - Drop out Cut Out
HRC fuse - High Rupture Capacity fuse
OH - Overhead
DB - Distribution Box
LT - Low Tension
HT - High Tension
SS - Sub Station
PB - Pillar Box
CG - Composite Gang
PMT - Pole mounted Transformers
DT - Distribution Transformer
SSM - Substation Maintenance
HT OPN - HT Operation
AOC -Area operation Centre
TBT -Tool box talk
PPE - Personal Protective Equipment
SPE -Special Protective Equipment
FBA -Finance and business Administration
PP - Project Procurement

Definition
Single Room S/S
11kv General Distribution S/S at which 11kv switch/ Isolator, Local transformer and LT panel
HT Bulk supply consumer panel room

3-Rooms S/S
1ST room for HT 11kv panels/ switches
2nd room for Local Distribution transformer/ Isolator
3rd room 8-way and 4-way LT panel installation with LT circuits

Load bearing structure


Civil structure without columns and beams

RCC frame structure


Civil structure with columns, beams and RCC roof
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Local Transformer
Transformer with capacity of 500, 750, 1000, 1250 and 1500KVA to be placed in a General Distribution
Sub-station

11KV HT room
11kv Oil circuit Breaker (OCB), Vacuum circuit Breaker (VCB) and Isolator

LT Panel room
8-way and 4-way LT panel installation with LT circuits

Ventilation
The forced ventilation system comprising fans, ducting and inlet/outlet vent must be designed, supplied
and installed

HT/ LT Cable Trenches


Trenches use to through incoming and outgoing HT/ LT cables safely inside substation

Road level
Floor level of substation compare with road level
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Section 3 - UNDERGROUND MAINTENANCE


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SCOPE:
This SOP is applicable to all UGM (KESC owned & 3rd party) employees working for HT / LT Cable
Maintenance & Laying Jobs being executed under supervision of UGM.

REQUIREMENT:
Manpower (KESC / Contractor/ 3rd party)

 Managerial (Skilled & Support)


 Field (Skilled & Support)
Material

 Fast Moving Critical Items - Materials with high AMC and high procurement lead times and in
absence of which schemes / jobs cannot be undertaken.
 Slow Moving Critical Items - Materials with low AMC and high procurement lead times and in
absence of which schemes / jobs cannot be undertaken.
 Fast Moving Non-Critical Items - Materials with high AMC and low procurement lead times and in
absence of which cannot badly affect the execution / completion of schemes / jobs.
 Slow Moving Non-Critical Items - Materials with low AMC and low procurement lead times and in
absence of which cannot badly affect the execution / completion of schemes / jobs

As per material management SOP # __ dated _______ and the user department has to arrange issuance
when the stock position at sub stores reaches at the quantity equivalent to average past consumption of 7
days for procurement lead times as mentioned for particular type of material

Action to Take

Close monitoring of particular material consumption trends over the past and future schemes in hand /
pending faults in hand in order to ascertain the desired quantities to avoid unwanted delays and piled up
schemes / faults.

Vehicles / Logistics
 Truck / MTL
 Testing Van
 Shovels

Communication Equipments
 Wireless Sets
 Mobile Phones
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Equipments / Tools

PPEs SPEs
Safety Uniform & shoes Earthing & Grounding Rod
Gum Bots Short / Ground Set
Helmet with Chin Strip Discharge Rod
Goggles Live Line Tester
Safety Harness Test Lamp
Front Positioning Belt Proper Tool Kit
Rubber / Leather Gloves

Digging Equipments Others


Shovels Electric Generator & Water Pump
Sledge Hammer Caution Boards & Traffic Cones
Hammer (Gun) Red Emergency Lights (Revolving
Chisel Fencing Tape & Hanging Arrangements
Spade Bamboo Ladder
Manila Rope Emergency Battery Torch (With Batteries)
Digging Rod Measuring Tape (Cotton and / or Metallic)
Mechanical Road Cutter Note Book & Paints
Grinder Machine
Testing Equipments Measuring steel tape 3.5m
Surge Generator Emergency light (LED
Audio Frequency Generator
Fault Locator
Seismic Phone
Megger
Identifying Tools
Test Lamp
Connection Leads
Earthing Leads
Clip-on Device

Jointing Equipments & Tools


Hydraulic crimping tool
Gas Cylinder & Gas flame torch
Hacksaw frame with insulated handle
Joints & ID / OD Terminations
EPR Tape PVC Tape
Combination pliers 8"
Screw spanner (12"& 10")
Screw driver (12" & 16")
Ring & Fix spanner set with insulated handle
Ratchet socket set (40 pieces) with insulated handle
Cable cutter (ratchet type) with insulated handle
XLPE cutter (pipe cutter) with insulated handle
Semi cutter (paper cutter) with insulated handle
Knife with insulated handle
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Approval From Management


Budgetary, SUB-ER and AUC Approvals

Approval From different Civic Agencies and utility agencies.


ROW / road Cutting approvals from different civic agencies which include but not limited to CDGK, TMAs,
District administrations , Cantonments, industrial estates, Pakistan Railways, DHA and NHA etc. Utility agencies
require detailed information about excavation works to be undertaken by KESC in order to safe guard their
underground utilities running along the intended cable routs. These agencies included but not limited to PTCL,
KW&SB, SSGC, Oil Refinery companies, Fiber optic and other telecommunication underground utilities and etc.

FUNCTIONS
UGM SUB UNITS:
This department comprises of 3 sub units, a control room, a testing unit and a jointing unit. There is one control
room in each region where all fault information is received from OCR. After evaluating the fault type and
determining the type of work required, it is forwarded to one of its sub units, UGM Testing Unit or UGM
jointing unit.

UGM CONTROL ROOM:


Primary responsibilities of UGM Control Room are as follows:

 Coordinate with testing and jointing units for resolution of underground faults;
 Maintain inventory of material required by testing and jointing units;
 Arrange trucks to transport material from the material store room to fault site;
 Coordinating between the CEO/City Nazims / Cantonment boards CEOs / DHA etc with the help of AM /
Manager / DGM UGM for excavation of road(s) to expose faulty cable
 Maintain a daily fault resolution sheet that is forwarded to the relevant OCR;
 Maintain High Tension (“HT”) / Low Tension (“LT”)log book(s) and update fault status;
 Maintain a jointer’s gang sheet that contains details of the location of each gang(s) and the faults they
have been assigned to;.
 Email the status sheets daily to the respective regional GM and Director Operations .

UGM TESTING UNIT:


Primary responsibilities of UGM Testing Unit are as follows:

 Ensure visit of the testing crew to the fault site and take necessary action;
 Coordinate with the contractors concerning equipment testing ( Not done by HT UGM Testing Section )
 Ensure proper fault localization through suitable testing processes.

UGM JOINTING UNIT:


Primary responsibilities of UGM Jointing Unit are as follows:
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 Repairing / jointing of cables;


 Laying / commissioning of 11KV feeders.
 Preparing HT cable joints for rectification of cable faults;
 Prepare indoor / outdoor cable terminations;
 Remove faulty cables and install new cables .

ROLES & RESPONSIBILITIES: GM Infrastructure and GM HT

GM Infrastructure (Project Owner)

 Monitoring all activities of subordinates and contractors during planning & execution of Schemes /
Proposal.
 Ensures progress of the Schemes / Proposal in coordination with department and stake holders.
 Resolves internal and external conflicts by providing guidelines and defined procedures.
 Development of SOPs covering every aspect from conflict handling till capitalization of Scheme / Proposal.
 Counter verification of invoices & bills.
 Timely preparation / updating of Cable Route Sheet Soft/ Hard copy to Operations Dept.
 Arranging for trainings as recommended by DGM through L&OD.

GM HT

 GM – HT to oversight all above mentioned activities and fulfill requirement of tools, equipment, PPEs,
SPEs and logistics for field staff along with material management.
DGM ( Infra structure )

 Execution scheduling & implementation to complete the projects within given timelines.
 Site visit at least once a week to monitor progress of work and record checks.
 Arrangement of material through Manager (Planning & Support) & assigning jobs to execution team
 Monitoring targets & given assignments.
 Counter verification of invoices & bills.
 Monitor the stock position of material, process of material flow, stock at KESC, procurement process and
other resources availability.
 Creation of required MR/SR/AUC with coordination of other departments.
 Post execution evaluation after completion of task.

DGM UGM-HT

 Overall responsible for all jobs that will be carried out in HT U/G section pertaining to CM / PM /
New Connection / System Improvement proposal HT U/G work.
 Responsible for early rectification of fault.
 Co-ordinate / Arrange ROW permission / any other job from Civic Agencies / Cantonments Board /
CDGK / KMC etc.
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 Ensure proper inventory management in HT UGM.


 Ensure that all the work is carried out efficiently with maximum utilization of available resources.
 Review of annual budgetary Material requirements of HT U/G.
 Development of SOPs & procedures.
 Arrangement of Safety Trainings for HT U/G staff.
 Ensure that all Safety SOPs are followed on site /before start of work so that safe & accident work
can be carried out.

Manager Infra structure

 Managing Planning of schemes design & BOM.


 Co-ordination with FBA, Supply chain, Accounting & IM department regarding procurement &
availability of material and approval of AUCs.
 Acquisition of losses statement before & after execution from N/W Operations department.
 Initiates internal & external trainings for personal working as per staff jobs need
 Highlight the shortage of material.
 Site surveys for checking planning & monitoring quality & reliability.
 Track daily consumption of each material and track availability & procurement status.
 Track and follow up pending jobs for timely completion.
 Costs benefit analysis and closing of AUCs
 Priorities faults depending on nature and extend of damages done by the incidents.
 Scheduling & managing execution of a scheme / Proposals.
 Check that the targets assigned to Contractors are as per requirement and capability.
 Ensure that the execution is carried out as per timelines
 Check quality of cable laying & jointing work.
 Quality check & safety assurances
 Ensures good quality of equipment used by joint and testing gangs.
 Maintaining the record of invoices.

Manager UGM-HT

 Focal responsible for all jobs that will be carried out in HT U/G section pertaining to CM / PM /
New Connection / System Improvement proposal HT U/G work.
 Responsible for timely rectification of fault.
 Co-ordinate / Arrange ROW permission / any other job from Civic Agencies / Cantonments Board /
CDGK / KMC etc.
 Co-ordinate with HT Operations / IBCs / GSM /etc for surveys, issuance of estimates execution of
new connection schemes / System Improvement proposals etc.
 Responsible for inventory management (Issuance, credit, debit) in HT UGM.
 Ensure that all the work is carried out efficiently with maximum progress and utilization of all
available resources.
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 Forecast & Prepare annual budgetary Material requirements, critical Material requirements, Rain
Emergency requirement of HT U/G.
 Ensure that all Safety SOPs are followed on site /before start of work so that safe & accident work
can be carried out.

AM/AEE Infra structure

 Arrangement of site surveys along with representative from N/W Oprn. / NC department/ project
department for developing drawings & material requirement for schemes.
 Check drawings and BOMs of schemes as per surveys.
 Preparation of consolidated statement for the scheme.
 Preparation of documents for allocation of AUC.
 Issuance of material, PPEs from KESC stores.
 Preparation of MRs/SRs
 Verification of materials consumption / crediting statement of contractors/schemes / proposals.
 Keep Attendance & staff record & maintains record of all tools & equipments in office.
 Daily site surveys for execution & quality checks
 Facilitating all types of trainings for human development of the department.
 Enforcing compliance of all safety policies issued time by time.
 Management of record keeping of execution & material issuance, consumption and balance.
 Check & verify the invoices regarding material & works.
 Safety assurance, Tool box talk confirmation & PPE use check at site.
Management of Sub stores.

AM/AEE ( UGM-HT )

 Responsible of CM / PM / N/C / SI work in HT U/G work.


 Responsible for monitoring & supervision of HT faults / PM work / New connection work / S I proposal.
 Conduct survey with HT operations / IBCs / New connection / GSM for any related HT U/G work.
 Timely dispatching of Jointer / Testing / Lineman Teams on site in proper PPEs / all applicable SPEs.
 Co-ordinate with civic agencies for ROW for HT faults / SI Proposals / shifting of cable / etc.
 Material management.
 Ensure maximum output & progress of gangs as per available resources.
 Maintain the daily progress report of Jointer / Testing teams.
 Maintain record of Sub ERs / SI Proposals / Faults /etc.
 Ensure that all works are carried as per approved Safety rules, procedures & policies.
 Ensure that safe & accident free work is carried out.
 Ensure that gang receives requires tools, equipments & material for quick resolution of the assigned job.
 Check & verify the invoices regarding material & works.
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Associate/Assistant/Sub Engineer/ Supervisor ( Infra Structure )


 Survey of proposal along with representative from N/W Operations & NC.
 Prepare drawings with cable lengths, no. of cable Joints & GI Pipes and RCC Pipes outgoing cables of
services.
 Updating drawings for newly made joint cable extension and other modification.
 Conduct pre installation surveys to ensure smooth execution of scheme.
 Supervision at site during execution.
 Achieving daily targets of execution & daily reporting of material & works at site.
 Quality check & safety maintenance.
 Verify the invoices regarding material & works.
 Responsible for Feeder route Sheet complication.

Associate/Assistant/ EMO (Control Room) (UGM-HT )

 Responsible for timely dispatching of Jointer gangs / Testing Gangs /Lineman gangs on site for CM
/PM / New connection / SI Work.
 Ensure that gang receives all tools, equipments & allied Material to attend the job.
 Ensure that all the assigned jobs are executed in minimum possible time.
 Timely up dation of faults / job status to AM /Manager /Dy. GM UGM.
 Ensure proper credit of Material after the job is attended in coordination with HT UGM Sub Store.
 Co-ordination with HT Operations / HT SSM for timely arrangement of shutdowns, fault
forwarding, fault clearance , fault status updation etc.
 Prepare a daily progress report of all teams.
 Prepare a monthly fault rectification / jobs attended report.
 Ensure that all work is carried as per Safety rules & SOP.
 Ensure that all gang receives TBT , PPEs , SPEs before being dispatched on site.
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Associate/Assistant/Sub Engineer/ Supervisor ( Infra Structure )_ - Material issuance:


 Debits notes / DTN preparation & materials issuance from stores.
 Credit of balance material from scheme at KESC stores & keeping the record of credit notes.
 Maintain the record and copies of debit/credit notes / DTNs and gate passes.
 Check quality of work at site on daily basis.
 Conduct inspections with respect to specification & utilization for procurement & delivery.
 Maintain material record with debit note, gate pass entries in registers.
 Compile the overall up to date statements of material on daily basis.
 Ensuring all safety policies are followed.
 Posting of daily issuance/use /credit of material and compiling daily material/inventory statements.
 Posting of daily works reports from site.
 Posting of daily attendance and daily gang formation.

Associate/Assistant/Sub Engineer/ Supervisor (Testing/ Underground) (UGM-HT )

 (Testing )Ensure that the faults is Tested , Pinpointed , rectified in minimum time as possible
 (Testing )Attend all the Jobs of Cable identification, cable route tracing, fault PP, R/P/P as assigned by HT
U/H control room.
 (U/G ) Supervise & monitor the HT U/G fault / PM work / New connection work / SI work as assigned by HT
U/G control
 (Testing / U/G ) Carry out surveys for SI Proposals, PM , New connection HT U/G work / etc.
 (Testing / U/G )Ensure that all work is carried out as per Safety SOPs, rules & procedure.
 (Testing )Prepare route sheets; carry out physical route check of Feeder / HT Links as assigned by HT U/G
control.
 (Testing / U/G ) Ensure that TBT is carried out before being dispatched and start of work.
 (Testing / U/G ) Record all the activities of gangs on HT Fault log book.
 (Testing / U/G ) Perform any other assigned job as desired by U/G Control / AM / Manager.

UNDERGROUND MAINTENANCE – Process Flow


UGM’s primary responsibility is cable jointing on poles and PMTs under fault conditions. Following are the
steps to follow in execution of maintenance jobs. (Corrective Maintenance).

Step – 1 Team Formation ( Infra Structure.)

a. Supervisory Services Officer / Supervisor (1)


b. ( Excavation Supervisor, Supervisor Electrical) (At least A.E,Sub Engineer) (1)
c. Contractor Labour (As per cable length) (2)

Jointer Team Formation:


a. Supervisory Services Officer / Supervisor ( Supervisor Electrical / Excavation Supervisor / Sub Engineer )
b. Cable Jointer / Cable Jointer Services
c. Semi Skilled Cable Jointer
d. Karkun / Help Support Services ( 02 – Karkuns in 01 – Jointer gang )
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e. Excavation contractor labor

Lineman Team:
a. Supervisory Services Officer / Supervisor
b. Lineman/HT/LT Line Maintenance Services
c. Semi Skilled Lineman
d. Karkun / Help Support Services

Step -2 Fault Declaration & Mobilization


a. After isolating the faulty cable / portion, OCR will inform UGM control room (CR) of fault through wireless
/ intercom / landline. M&C can also inform UGM directly of LT fault via wireless / intercom / landline.
UGM CR can also view the total outstanding faults in the daily fault sheet sent by OCR over the period.
b. Shift In charge (“SI”) will immediately acknowledge fault and simultaneously register relevant details such
as date & time of fault reported, nature of fault (if visible), link, feeder name, S/S name, PMT name,
position of transformer., switch, fault location, person who forwarded the fault in the HT / LT faults
register.
c. SI will then verbally communicate fault details to the testing In-charge.

Step – 3 Cable Identification (Where required)


a. Cable identification is a procedure by which the position of required cable is located among many Live
(On), dead (Off) or abundant Cables by using Audio Frequency Generator and Frequency searching
coil/route tracer.
b. Following steps are followed:
 Complete shut-down of cable at both ends.
 Cable sheath (GROUND) open at both ends of cable.
 At far end two cores to be looped by (core to core method)
 At far end core to be looped with sheath of cable (sheath to core method)
 Identify desired cable and confirm
 Pickaxe/create fault at desired cable using standard nail.
 Use surge generator to hear fault sound then cut the cable.

 Ground Audio Frequency generator at protective earth terminal


 Setting of output impedance with adaptation or manual impedance adjustment.
 Manual setting of standard frequency 10KHZ/2KHZ at Audio frequency generator
 Set Frequency receiving searching coil 10 KHZ/2KHZ

Traditionally we are using others Cable identifiers and following steps are incorporated with above 07.

 The transmitter is connected with the two cores that are looped at far end with confirmation by taking
continuity of the same two cores that have been looped.
 The receiver is then taken to the far end where the cable has to be identified
 The identifier will then give the beep / sound signal which will tell that this is the required cable.
 If sound is coming on more than one cable we will select the cable on which the sound and most clear
and maximum.
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Step - 4 Fault Testing


a. Testing In charge will inform the testing team via mobile of the fault details and instruct the team to
visit the fault location for fault testing.
b. Testing team will visit the fault location and as a precautionary measure will firstly check if portion is
isolated. Testing team will also check through an 11KV tester if the cable is discharged by checking both
ends (SS or grid).
c. Testing team will search if the fault lies in core 1, core 2 or core 3 and in case of LT check core 4 by
pressure test.
d. If cable is OK in pressure test, then testing team will inform UGM CR via wireless /mobile phone of fault
clearance.
e. If fault persists, testing team will measure the fault distance with pre locator machine. After the distance
is confirmed, will apply surge generator and pin point the fault, mark the same and inform UGM CR via
mobile phone alternatively the testing In charge is informed if contact with UGM CR is not established.
f. After cable is exposed, the testing team will test again to reconfirm the fault area in the presence of
jointer gang. If jointer is not present, the same is informed to UGM CR for further action.
g. After cutting and preparation of termination ( Pressure end ) of both ends of the cut cable and clearance
from jointer, testing team will apply pressure to the cable ( only one side) and will see the niddlle if
Pressure sustained.
h. If again Pressure not sustained which indicates further / duplicate fault the fault localization procedure
would be repeated.
i. If both portions are found healthy, testing team will inform jointer to prepare joint and will finally
pressure the Main cable after joint is made in order to determine if fault is resolved and then after
testing team will inform UGM CR for connection of cable to the RMUs and Switchgear / VCBs of Grid
Stations / Poles / PMTs / Sub-Stations through Linemen / Jointer in case of cable end nature of fault.

Step – 5 Road Cutting Permission


a. A written request for road cutting is submitted to head of relevant Civic Agency. This written request is
sent to concern authorities only once when the fault area is confirmed by the testing team. Along with
the written request, UGM CR also calls and informs the authority of the excavation request.
b. If the fault is PP in late hours / night hours concerned civic agency will be informed verbally and if not
possible gang will execute the excavation work with having emergency Performa with them.

Step – 6 Excavation
a. Once the road cutting permission is granted (if required) from the concerned civic agencies (Town, CDGK,
KPT, DMC’s, Cantonment, Site Limited, NHA etc), excavation process begins.
b. Depth/Level of excavated ground should be as per the standards defined by IEC i.e. 1meterWhen laying the
cable, supervisor should ensure the proper depth of the excavated ground.
c. If 1 Meter depth cannot be achieved due to any hindrance in excavation i.e. Rocky soil, Utility Lines passing
across and hard concrete floor, maximum possible excavation that could be carried out will be done. GI &
Hume pipes are to be used to pass the cable through the part of the land which will create hindrance when
excavated in future e.g. Factory gate, road crossing, Railway crossing, sewage line, and open sewage NALA
etc.
d. After the cable has been laid, warning tiles are placed over the laid cable.
e. Back filling and leveling work of ground is done in the end.
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Step – 7 Material Issuance


a. The material requisite form is duly filled and signed off by the relevant authority (Supervisor UGM CR, on
duty staff at the store room and the jointer) for material and relevant PPEs and SPEs issuance. All these
details are recorded in the HT / LT faults register.
b. Store keeper will then issue required material as per the approved material requisite slip and he will
simultaneously note down relevant details such as jointer’s name, material & job details in the gate pass
book. (Approved and signed by store keeper, jointer and UGM CR staff) and hand it over to UGM CR. SI will
log the gate pass number and material details in the HT / LT log register.

Step – 8 Material Transportation


a. SI will arrange for the truck and driver to deliver the material along with the jointers team to the fault
location. The gate pass slip is then handed over to the jointer’s team. (for materials) The truck driver will
simultaneously fill in the security slip, valid for whole day, approved by UGM CR for truck entrance and exit
permission in KESC premises.
b. Truck driver will show the security slip to the security guard and enter KESC premises to load the material
in the truck to transport them to the fault location.
c. Once material is uploaded in the truck, the gate pass is shown to the security guard for permission to take
the material outside the premises to the fault location.

Step – 9 Fault Correction / Jointing


a. On confirmation of the end fault, if the cable is mounted on the pole, a lineman gang is dispatched to drop
the cable where needed.
b. SI will dispatch lineman gang to pull down the cable for testing and repairing and to hang leads for testing
and inform to Testing team Incharge / UGM CR.
c. Testing team Incharge / UGM CR will then arrange to send the jointer’s team to excavates (Termination
fault ) and look for the loop of the cable, disconnect / remove all the damaged cables. Required material
such as HT joint, termination kit, EPR tapes, PVC tapes, 11 KV tester, etc. are sent along with the jointer’s
team to repair fault.
d. On reaching the fault location, the cable jointer will ask the laborers (outsourced) to excavate the pin
pointed area to expose the faulty cable / portion, ensuring first that road cutting intimation to concerned
Civic Agency is handy at site.
e. After re-confirmation of fault area once exposed cable jointer will cut the affected portion of the cable.
f. For terminations If only 1- core / 2- core is damaged of HT Termination only the required material of 1-
core / 2- core is used for HT Termination repairing. Also loose Bi Metallic Lugs are used wherever required
to repair the HT Termination
g. After cutting the faulty cable, the cable jointer will make pressure ends of both ends of the cable for the
testing team to apply pressure and to reconfirm if the fault is removed or exists in the cable.
h. After confirmation from testing for the soundness of the both the cut portions cable jointer will repair
faults / make joints with relevant material (XLPE of the cable is to be cleaned precisely with Kerosene oil)
and will inform testing for final pressure to determine if fault is resolve. When laying a cable piece, the
bends in the cable should be minimal.
i. Contract laborers will then re fill the excavated portion of the road to cover the cable as a temporary road
repair.
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Step – 10 Fault Closure


a. SI will update OCR of the fault clearance and log date, time and SE’s name (OCR) in the HT / LT faults
register.
b. Cable jointer will come back to the centre and return all unused material to the store keeper in the
material store room.
c. SI will verify and check the returned material from the material requisition slip and log the used and
unused material in HT / LT faults register the returned material details will also be logged in by store keeper
and by UGM CR.
d. UGM will log fault clearance, along with all relevant details in the HT / LT log register and close case.
e. Before dispatching any jointing team, P.P.Es / S.P.Es and working tools shall be checked comprehensively
by Dispatch Supervisor.

HAZARD ASSOCIATED WITH CABLE JOINTING


Slipping during excavation/digging work.
Electrical shock.
Mechanical hazards.

Implementation of SIP / NC Proposals

UGM’s job domain also includes installing, testing, replacement, repairing and energizing new cables through
SIP Proposals & NC Proposals.

a. After the receipt of proposal for new 11 KV cables from concerned IBC / HT operations / NC
department(send the completed case file with execution plan and cable route to HT UGM ), joint survey of
sites are to be conducted by officials of concerned IBC / network operations / NC and UGM department for
finalization of the route of the cables.
b. Preliminary route sheets / Drawings / Sketch are to be prepared and jurisdiction of respective civic agencies
i.e. KMC / CDGK, DMC, Cantonment Boards, SITE Ltd. Port Qasim, KPT authorities and NHA etc. are
marked and identified.
c. Standard KESC Drawing for cable laying & BOMs for new schemes/feeder/link proposals shall be prepared
by concern department (IBC / UGM / NC) and shall be got approved by concerned Departmental Head.

PROPOSAL (Approved SIP SOP to be followed ) / SUB-ER / NEW SCHEMES PROCEDURE


a. First of all approved Sub-ER file is received from Planning to UGM Department.
b. Manager UGM go through file and if there is no any discrepancy in the given file then he will assign AM/AE
to execute the work as per KESC policy
c. On SF Schemes the consumer will award the work to KESC approved PQC (with submission of work letter
and concerned documents as per SOP.
d. A.M/A.E of UGM conducts the survey of required site along with representative of KESC Qualified
Contractor.
e. The survey report is submitted to Manager UGM.
f. If survey report is Okay then Manager UGM instruct to A.M to prepare the Debit Note (if full paid new
connection scheme) as per Material List and Draw the Material from central Store as per AUC No.
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g. In self finance scheme if the material is found as per BOM of Planning department , Material list will be
issued to the consumer / PQC authorized by Consumer who will purchase the Material as per KESC
standards & specifications
h. In Self finance scheme the consumer will purchase the Material from KESC approved vendor and inform /
request to Manager UGM office for inspection letter of the same material with all supporting documents
,test reports , receipts so that the inspection can be carried out in CS / site ( SOP will be followed).
i. After the Inspection ( OK Report ) Applicant / PQC will be informed to provide the start of work letter in
office of Manager UGM.
j. After receiving of the Material, the Qualified Contractor starts the excavation and laying of cable work after
providing the start of work letter in HT UGM and availability of valid ROW from concerned civic agency with
supervision of KESC HT UGM supervisor ( Self finance scheme )
k. After completion of excavation and laying of cable, the Pre Qualified Contractor informed to Manager UGM
through a work completion letter ( self finance scheme ) .
l. Required site is checked by KESC team that work is done as per KESC policy

m. In case of full paid scheme the KESC HT UGM- AM will show the site to KESC approved PQC who will
transport the HT cable from KESC Sub Store to Site and then lay the HT cable as per KESC standards and
specifications subject the valid way leave provided from the consumer.
n. Then jointing, termination and hanging of cable (if required) is done by UGM Staff. ( in case of full paid
scheme )
o. In case of self finance scheme dead side work is done by KESC Approved PQC in supervision of KESC
supervisor.
p. After completion of jointing and termination work by UGM staff, Manager UGM will submit the Shut down
form to Operation Department for connecting the cable.
q. After connection of the cable, clearance of UGM department will be sent to operation department as well
to NC / Planning

WAY LEAVE PERMISSION OF RIGHT OF WAY FOR CABLE LAYING


a. For the NC proposals (other than full paid) (ROW is arranged by applicants in both case both in SF & Full
paid) ROW is to be arrange by applicant and to inform KESC to initiate the execution.
b. For SIP proposals request letters for getting ROW are prepared / submitted to head offices of respective
civic agencies falling on the route of the proposed cables.While for all NC Cases the core responsibility is of
Applicant who will provide the valid Road Cutting Permission .
c. For SIP / Feeders Survey with Officials of concerned agencies are conducted and measurement of
roads, footpaths, kacha portion, green belts, sewerage lines and/or railway lines that are falling on
routes of cables are being carried out and locations for thrust boring (if required) are identified.

d. If the concerned authorities (town / city government / KWSB / Sui-gas / NHA / Railway etc) suggest any
amendments in the KESC approved drawings of the route for cable lying, the same shall be intimated to
KESC. If approved by KESC, the amended drawing will again be prepared and shall be submitted to the
concerned way leave authority
e. Challans / bills for road cutting charges are prepared by respective department / agencies,
requesting KESC to deposit charges.
f. Checking / verification of challans of road cutting charges is carried out by the Officials of UGM,
discrepancies found if any, are pointed out to concerned agencies for rectifications.
g. KESC will verify/reject the bill/ROW charges within 07 days of the receipt of bill.
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h. The duration and dates of start and ending the work given in the permission must conform to the period
and dates during which the actual work will be executed.
i. The consent from the concerned agencies for adjustment of claimed charges is acquired.
j. Approval for the payment / adjustment of road cutting charges is solicited from Management.
k. After submission of cheque / adjustment of claimed amount towards road cutting charges the NOC/ way
leave permission is granted by the respective agencies, enabling KESC to mobilize the pre-qualified
contractor and start the excavation work at site.
l. After getting ROW NOC from civic agency, different utility agencies like PTCL, KW&SB, Refinery Companies
and other telecommunication departments are to be intimated for the intended excavation and cable
laying work by clearly mentioning routes and dates for the same to look after and identify their services
during execution of KESC in order to avoid unexpected damages to the public utilities The arrangement for
diversion of traffic if required and to get the route clear from all other utilities/organizations before, during
and after the cable laying shall be the responsibility of concerned UGM.

EXCAVATION OF TRENCH & LAYING OF UNDERGROUND CABLE


a. Excavation of the cable route shall be carried out as per KESC Approved Drawings..
b. The Standard Excavation of single cable trench shall be ½ meter x 1 meter and for additional cable it shall
be 15 cm x 1 meter. The excavation shall be done in all types of soils. After the trench has been properly
made, proper bedding for laying the cable shall be made in the following manner:
c. After excavation has been completed and trench has been made out as per dimensions described, a layer
of 15 cm of the fine sand shall be provided over the entire length of the trench and then cable is laid and
lying of cable will be done on site on rollers ( if Available ) which should be placed at suitable distance so
that the cable is not dragged on the soil.
d. After cable is laid, back filling by 15 cm of fine sand with proper compaction shall be done, so that the total
sand height is 30 cm.
e. Warning tiles will then be placed on top of 30 cm laid fine sand after partial back filling by normal soil upto
200mm in accordance with enclosed drawings.
f. The warning tape (yellow/orange) shall be laid after partially back filled normal soil 200 mm above cable
warning tile as shown in drawings enclosed
g. The cable trench will be back filled with normal soil and compacted up to ground level as shown in
enclosed drawings
h. The same procedure is to be adopted for cables to be laid in rocky soil / normal soil
i. Cable will be laid in loop prepared at the point of jointing of cable pieces and shall be excavated in ‘S’ shape
where ever required.
j. When laying a cable, the bends in the cable should be minimal
k. Where ever the cable is terminated i.e., Sub-Station/RMU/PMT poles, cable will be laid in loop excavated
in shape of ring of not less than 5 meters approximately to cater for cable termination/end faults
l. Cable lying across road and railway track will be done by horizontal boring either with hammering or
pressure /machine boring
m. Whenever cable is to be laid across road/railway crossing, cable shall be laid inside G.I. Pipe of 6 inches dia
n. At sub/branch road crossing, in front of gate of residential plots, sewerage/drains (Nala) crossing cable shall
be laid inside Hume Pipes (RCC)
o. In case the excavation is to be done near old cable route, extra care has to be exercised so that no damage
occur to the live cable running nearby.
p. KESC site staff shall use all necessary PPE and follows safety precautions at the time of lying of cable.
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HAZARDS WITH CABLE LAYING


Slipping during excavation / Digging work
Mechanical hazard

MODE OF TRANSPORTATION AND LAYING OF CABLE


a. Transportation of complete drums
b. The cable will be lifted in form of drum from KESC Central Store. The cable will thus be transported to the
site of laying in this way that un-rolling, and lying of cable will be done on site on rollers which should be
placed at suitable distance so that the cable is not dragged on the soil. The vehicles, lifter, trolley, jack,
rollers; whatsoever required in the process, will be made available for work at all the times.
c. The cable drum when emptied at site shall be credited at KESC Store Baldia.
d. Transportation of Part Length (Less than 250 meters)
e. Part length of cable is to be transported by loading it on a truck in a figure of ‘8’. Care is to be exercised
that the radius of bend is not less than 03 meters and cable is not damaged

CLEARANCE OF WAY
a. The concerned UGM will be responsible for clearance of all obstacles in lying before, during and after
execution including drainage/pumping of water from trench to ensure suitability of trench for cable laying
b. The clearance of Debris or any other material lying in the route of the cable shall be the responsibility of
the concerned UGM

JOINTING & TERMINATION OF CABLES


a. HT straight through joints will be made to connect HT Cable lengths/pieces. Similarly HT terminations will
be made at the end of the routes and connected at Grid Stations, switches, ring main units, HT Poles of
PMT & in Sub-Station
b. Depending on whether cable is to be mounted or is in S/S or RMU, different lengths of cable are used. I.e.
12 meters in the case of S/S, 18meters in the case of pole mounted and 10meters for the RMU.
c. Cable Destination must be printed at Grid Station switches as well as Sub-Station switches/Isolators and
RMUs
d. Cable destination must be provided with the help of metallic embossed Tag for over head to PMT, PMT to
PMT or PMT to otherwise
e. Shutdown arrangement shall be the responsibility of UGM department for identification of the cable in
case of new and old cable jointing. Special care should be undertaken by UGM Department that the cables
are properly tagged also
f. Shutdown & Clearance of 11KV Switch from GSM & Protection Department shall be obtained by UGM
Department before connection /energization of newly laid main cable as well as Clearance of Sub-Station
Switch/Isolator & RMU in concerned operation department.

HAZARD ASSOCIATED WITH PREPARATION OF CABLE JOINT / TERMINATION


Fall from height
Electrical Shock
Mechanical hazard
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Cable Joint Marker


a. Clearly visible Cable Joint marker shall be installed over the joints locations for the purpose of identification
of HT Cable Joints
b. In case of cable fault if any additional joint/joints are installed on the route of the existing cable, Cable Joint
Mark shall be installed at all such new cable joints
c. In rainy and windy weather, a shelter tent shall be erected over the joints pit for protection against rain
and dust

Megger & Pressure Testing


a. Each of the cable drums will be tested for continuity & insulation test.
b. After lying of cable, with joints if any or otherwise, shall be pressure tested so that the soundness of
joint/termination is also ensured before connecting it to KESC Medium Voltage Distribution Network
c. The UGM department shall ensure proper earthing of the cable to KESC Distribution system, the earthing
braid given in termination kit shall be connected with single Core 70 mm2 PVC copper lead which will in
turn be connected to earthing system in place of earthing braid.

Cable Route sheet/drawing


a. After laying and energization of the cable, the finalized drawings in triplicate shall be prepared on Auto-
CAD/ MS Visio with soft copy on CD along with hard copies on paper and butter paper (for future
development of Ammonia prints and should be updated every year in new populated area.
b. The finalized Cable laying Route drawings shall be prepared to the scale of 2000: 1 and shall include
necessary information e.g. physical direction, glossary, roads railways, buildings and other structures, route
of cable, location of joints, G.I. pipes, Hume pipes, clearances from property side, roads, footpath, etc shall
all be clearly indicated in the Cable laying Route drawings
c. The route sheets shall indicate the exact location of joints with exact measurements along the route and
across the road.
d. Duly approved hard copies of drawings along with soft copy on CD shall be maintained in the record room
of UGM Department and any up gradation or alternation in the existing cable route sheet shall be
incorporated as and when required

SAFETY PROCEDURES AND PRECAUTIONS FOR HT CABLE LAYING :

GROUNDING OF CABLE SYSTEM:


 For safety and reliable operation, the shields and metallic sheaths of power cables must
 be grounded. Without such grounding, shields would operate at a potential
 considerably above ground. Thus, they would be hazardous to touch, and would incur
 rapid degradation of the jacket or other material intervening between shield and ground.
 This is caused by the capacitive charging current of the cable insulation which is
 approximately 1milliampere (mA) per foot of conductor length. This current normally
 flows at a power frequency between the conductor and the earth electrode of the cable,
 normally the shield. In addition, the shield or metallic sheath provides the fault return
 path in the event of insulation failure, permitting rapid operation of the protection
 devices.
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GROUNDING OF CONDUCTOR:
 The grounding conductor, and its attachment to the shield or metallic sheath, normally
 at a termination or splice, should have an ampacity no lower than that of the shield. In
 the case of a lead sheath, the grounding conductor must be able to carry the available
 fault current over its duration without overheating. Attachment to shield or sheath is
 frequently by means of solder, which has a low melting point; thus an adequate area of
 attachment is required.

RECOMMENDATIONS:
 Do not leave one end ungrounded, as that may create high voltages on the ungrounded end and may
jeopardize system/equipment/personnel safety.
 Do not leave Ground strip disconnected.
 Do not used under size wire for ground strip.
 Do not use Cable Strip via binding wire at Substation.
 Follow only set standards for connecting earth strip.
 Inappropriate cable termination.
 Follow standard operating procedure for grounding.
 Strict logging for actual reasons of cable fault be maintained.

GENERAL SAFETY MEASURES

 Before start of work at site, tools box talks shall be arranged by the Site Engineer/Supervisor for all staff
deputed to carrying out designated work of intended activity.
 Site supervisor shall ensure that all KESC staff working at site is properly equipped with necessary
PPEs/SPEs before start of any activity at site
 Caution Notice/Flags and danger board sign shall be placed near work place
 Arrangement of emergency lights shall be made available for site work carried out during night
 All shutdown arrangements regarding lying, jointing, terminating, testing and commissioning /energization
shall be carried out as per standard safety procedures.
 To Ensure complete shutdown of cable at both ends .
 Physically checking both ends of cable.
 Use of SPE’S / Live line tester /discharging rod.
 Proper Grounding / Earthing of instrument.
 To ensure required cable is exposed clearly at least 12’ from all sides at desired place.
 After identification Nail to be used for pick axing.
 After pick axing, cable to be re-confirmed by HIPOT method.

HT CABLE JOINTING.
 After confirmation of Isolation of Faulty cable from Operation Testing team will be dispatched on site with
applicable PPEs /SPEs and they will PP the Fault then inform the Jointing team to reach the fault location.
 The first and the foremost step taken by the jointing team is to confirm the exact location of the fault and
confirm from operation that cable is isolate. The road cutting intimation Performa will be submitted in
office of concerned civic agency and if the fault is PP in late hours / night hours concerned civic agency will
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be informed verbally and if not possible gang will execute the excavation work with having emergency
Performa with them.
 Once the road cutting permission is granted ( if required) from the concerned civic agencies (Town, CBC ,
DHA, CDGK, KPT, DMC’s, Cantonment, Site Limited, NHA etc), excavation process begins and continue till
the faulty cable is exposed.
 Jointer must ensure proper tools required for cutting/splicing the faulty cable before jointing.
 Ends of the cable are made for cable pressure test for testing team.
 Jointing / Termination work begins with cutting different layers of the cable as per IEC standard and precise
measurements mentioned in the joint manual.
 Layers include cutting of Outer sheath, armoring, inner sheath, copper screen, outer semiconducting
tape, XLPE, inner semiconducting tape, aluminum core strands.
 XLPE of the cable is cleaned precisely with Kerosene oil.
 Moisture/water vapors/ air gap/ vacuum content are avoided near the jointing / termination ends.
 Depending on the type of joint used (Elastimold, Raychem, heat shrink etc), different steps are taken to
ensure a proper joint.
 If complete HT joint is not available due to any issue i.e. Non- availability, extreme shortage etc. Joints will
be made with loose Material i.e. HT Ferrules 300mmsq , EPR tape.
 Excavation for HT- cable loop will be carried out and if HT- cable loop not found HT-cable piece will be laid
to clear the HTCF
 Back filling and leveling work of ground is done in the end.
 Clearance is given to the UGM- control after completion of work.

Drawings
 Single HT underground cable laid in Trench
 DRG No.1 K/D/TPRE/SOP/CABLE LYING …….2013
 HT underground cables laid in Trench
 DRG No.2 K/D/TPRE/SOP/CABLE LYING …….2013

FORMS / DOCUMENTS:
 Preliminary Survey from.
 Preliminary route sheets / Drawings.
 ROW (Letters).
 Survey from (prepared with different civic agencies representative).
 Road cutting challan (receive from different civic agencies.
 Approval letter from Management (for the payment / adjustment of road cutting charges)
 Material (Debit / credit notes)
 Gate pass.
 TBT (Associate/Assistant/Sub Engineer/ Supervisor).
 Material verification / Record keeping Associate/Assistant/Sub Engineer/ Supervisor.
 BOM.
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DEFINITIONS:
SI Shift In-charge
OCR Operation Control Room
UGM Underground Maintenance
M&C Maintenance & Complaint
CR Control Room
LT Low Tension
HT High Tension
PPE Personal Protective Equipment
SPE Special Protective Equipment
SIP System Improvement Proposals
NC New Connection
PP Pin point
AMC Average monthly consumption
CS Central Store
DHA Defense Housing Authorities
CDGK City District Government Karachi
KW&SB Karachi Water and Sewerage Board
TMA Town Municipal Administration
NHA National Highway Authority
PTCL Pakistan Telecommunication Company Limited
SSGC Sui Southern Gas Company Limited

Definition
Disconnect
Isolate the portion of network on which shutdown is to be arranged to carry out a specific job.

Test for absence of Voltage/supply


After disconnecting the portion of the distribution network through required operations, it must be
ascertained by testing the voltage on that portion of the system through live line tester by supervisor.

Earth and short circuiting


- Short circuit all the three phases of the portion of the network by a ground set or by a short circuiting rope /
wire to earth at a point with in visual range of the place of work. This must be carried out by a line man. The
Connection to the ground must be made before any other connections and removed last.

Isolation
A portion of network or electrical equipment that is removed from an electrical source. (HT & LT side).

Live Line Tester


A device used to test a circuit or equipment for the existence of voltage / power supply (HT by long and HT/LT
by small)
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Section 4 - Composite Gang


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INTRODUCTION:
One of the reasons for delay in fault rectification is the interdependence of maintenance gangs. Although the
scope of work for LT and HT is well defined, there remains certain LT fault for which further assistance of SSM
gangs and HT operations is necessitated, which adversely affects the TAT.

OBJECTIVE:
1. Reduction in “Fault Response Time” by increasing effectiveness of M&C gangs.
2. To improve SAIDI

WORKING PLAN:
Composite gang basically consists of nominated M&C gang reinforced with LT supervisor (trained on limited HT
operations and well versed with his area of operation, so as to obtain effective shutdown) and fitter along with
appropriate tools and material.

WORK FLOW
Composite gang work flow is defined as follows:

Note: HT faults are not shown in the work flow


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WORK SCOPE

Nominated Composite gangs shall give preference to attend primary faults as mentioned below over their
other routine complaints/ faults.

• Bushing to LT breaker lead repair and replacement


• LT breaker to DB lead repair and replacement
• DB to LT overhead lead repair and replacement
• Lead repair and replacement at LT panel (SS & pillar box)
• Repair and replacement of DB, SS, pillar box & fuse
• Base and base grip repair and replacement in SS , pillar box & DB
• Wire broken (LT)
• Replacement of faulty LT breaker

Attached is a standard format to record types of faults attended by Composite gang in “Annexure A”

TRAINING

DGM – M&C to conduct familiarization training on composite Gang work scope defined as above with all safety
considerations before formation of composite gang. Training shall be attended by Site supervisor, Dispatch
Supervisor, Lineman, Fitter, Karkun and concerned AOC staff.

Training will comprise of following:

 Technical training 
 Work scope familiarization 
· Safety training

GANG COMPOSITION:
There shall be a minimum of 3 composite gangs /IBC/day. The composition is as follows:

1. HT trained LT supervisor – 1
2. Line man – 1
3. Fitter – 1
4. Karkun – 2

The gangs shall be dispatched by dispatch supervisor.

ROLES & RESPONSIBILITIES:

1. 118 Response team:


 Timely forwarding of complains to MNC 
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 Coordinate with MNC and ensure all composite gang faults from MNC window and phone numbers
are also registered with 118 records.
 Record and maintain progress of composite gang on daily basis.

2. GM IBC
 He is overall in charge of Composite gangs in the IBC
 Collect a weekly composite gang report from Manager Complains and analyze accordingly
 Submit completion and evaluation outcome to DCDO & Director DS&P

3. Fitter
 Responsible for installing & replacing electrical wiring, equipment and fixtures.
 Ensure appropriate material is properly fixed in accordance with relevant plan and standards.
 Handle faulty meter and related shifting and maintenance.
 Assemble and install electrical wiring equipment, appliances and fixtures, using hand tools and
power tools
 Coordinate related maintenance work
 Repair of technical and electrical mains

4. L.M.O / Sk. / S.Sk. Lineman


 Off line Electrical works.
 Repairing of LT Jumpers/ leads, HT/LT wire broken
 Repair and construction of Busbars on PMTs
 Repair of DB to OH leads, HT jumper from busbar to D.O Cut outs
 Connecting / isolating LT cables, putting shorts on LT lines.
 Providing fuses in DBs
 Utilization of all PPEs prior to start the work.

5. Karkun
 Assist the lineman in performing his work.
 Maintain a favorable relationship with all KESC employees to promote harmonious working
environment
 Perform any other job as and when assigned by the management

6. DGM Networks
 Coordinate with GM IBC, DGM, Supervisors and gang to make sure work flow does not get disturbed

7. Maintenance Manager:
 Responsible for all activities regarding corrective maintenance.
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 Submit consolidated material requirement list (lugs, leads.. etc)


 Make sure all necessary arrangement are made for shutdown requirement and supervisors are
coordinating accordingly

8. Dispatch supervisor:
 On time and taking all the necessary material with them.

9. Site supervisor:
 Responsible for overall work on site
 Responsible for ensuring shutdown the line isolation policy before start of work.



MATERIAL MANAGMENT:
Material requisitioning and availability shall be the responsibility of respective IBC. They need to forward
consolidate material requirement list to respective Regional Material Coordinator RMC’s). The RMC’s
shall consolidate their regional demands and forward the same to GM - Coord DS&P.

The dispatch supervisor shall ensure the following material availability with each gang before dispatching
the composite gang from IBC;

 Material - leads, lugs, fuse base ,HRC fuse, LT breaker, DB, Nuts & bolts
 Tools - Crimping tools, torque wrench

PERFORMANCE MONITORING:
Performance monitoring will be done on Monthly basis by IBC Manager. It is recommended to use the
standard format attached in Annexure B

Performance of GM – IBCs be evaluated against reduction in TAT of faults (assigned in the work scope) as set
by DCDO.
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Section 5 - Universal Gang


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INTRODUCTION:
One of the reasons for delay in fault rectification is the remote areas due to distance to cover and
interdependence of HT and LT gangs. Although the scope of work for LT and HT is well defined, there remains
certain remote area where combination of HT and LT gang is necessitated, which adversely affects the TAT.

Scope of Universal Gang is widespread covering only remote areas as mentioned below; VIBC Uthal, Bela,
Memon Goth, Gadap & Gharo.

OBJECTIVE:
1. To improve SAIDI
2. Reduction in “Fault Response Time” by combining the HT and LT gangs.

WORKING PLAN:
Universal gang basically consists of dedicated M&C gang reinforced with HT supervisor well versed in his area
of operation, so as to obtain effective shut down and fitter along with appropriate tools and material.

WORK FLOW
Universal gang work flow is defined as follows:
Complain Received from 118,
Complaint received at CC
Telephone or Window

Universal Gang

Attend
w/o
Shutdown

NO Shutdown Request from OPN


control
YES

Complaint Supply Check


Note: All HT/LT faults Resolved Short & Ground
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WORK SCOPE

Dedicated Universal gangs to attend all HT/LT faults as mentioned below;

• Bushing to LT breaker lead repair and replacement


• LT breaker to DB lead repair and replacement
• DB to LT overhead lead repair and replacement
• Lead repair and replacement at LT panel (SS & pillar box)
• Repair and replacement of DB, SS pillar box & fuse
• Base and base grip repair and replacement in SS , pillar box & DB
• Wire broken (HT/LT)
• Replacement of faulty LT breaker
• HT jumper
• Main/Service Jumper
• Bus bar Jumper
• D.O Jumper
• Link fuse

TRAINING

DGM – M&C to conduct familiarization training on work scope defined as above with all the safety considerations
before formation of universal gang. Training shall be attended by HT supervisor, Dispatch Supervisor, Lineman,
Fitter, Karkun.

Training shall comprise of following:

 Technical training
 Work scope familiarization
 Safety training

GANG COMPOSITION:

 HT supervisor – 1
 Line man – 1
 Fitter – 1
 Karkun – 2

ROLES & RESPONSIBILITIES:


118 Response team:
 Timely forwarding of complains to MNC
 Coordinate with MNC and ensure all universal gang faults from MNC window and phone numbers are also
registered with 118 records.
 Record and maintain progress of universal gang on daily basis.
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GM IBC

 Overall in charge of Universal gangs in the IBC


 Collect a weekly universal gang report from Manager Complaints and analyze accordingly
 Submit completion and evaluation outcome to DCDO and Director DSP

DGM Networks
 Coordinate with GM IBC, DGM, Supervisors and gang to make sure work flow does not get disturbed

Maintenance Manager:
 Responsible for all activities regarding corrective maintenance.
 Submit consolidated material requirement list (lugs, leads.. etc)
 Make sure all necessary arrangement are made for shutdown requirement and supervisors are coordinating
accordingly

Dispatch supervisor:
 On time and taking all the necessary material with them.
 Ensure Daily TBT

Site supervisor:
 Responsible for overall work on site
 Ensure TBT on Site
 Responsible for ensuring shutdown, line isolation policy before start of work.


MATERIAL MANAGMENT:
Material requisitioning and availability shall be responsibility of respective IBC. They have to forward
consolidate material requirement list to respective Regional Material Coordinator (RMC’s). The RMC’s shall
consolidate their regional demands and forward the same to GM - Coord DS&P.

The dispatch supervisor shall ensure the following material availability with each gang before dispatching the
Universal gang;

· Material - leads, lugs, fuse base ,HRC fuse, LT breaker, DB, Nuts & bolts
· Tools - Crimping tools, torque wrench etc.
· All necessary PPEs/SPEs

PERFORMANCE MONITORING:
Performance of GM – IBCs be evaluated against reduction in TAT of faults (assigned in the work scope) as set by
DCDO.

SAFETY CONSIDERATIONS:
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 Safety action will be clearly out lined in the work plan given by Manager/Supervisor
 All relevant safety procedures will be followed in letter and spirit
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Section 6 - Regional Workshop


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INTRODUCTION:
The concept of Regional workshop has been introduced to recycle un-serviceable material through this below
benefits can be obtained;
 Reduction in cost of operation
 Readily availability of material

Regional workshop shall cover IBC, SSM and UGM.

OBJECTIVE:
Repair through exchange - Workshop will maintain a pool of serviceable parts/assemblies and exchange it with
unserviceable assemblies/parts provided by user department. It will provide following advantages:
1. Time Saving
2. Cost saving
3. Focused to trade work
4. Optimum utilization of available resources
5. Better quality of workmanship
6. Assist in Preventive maintenance

WORKING:
Mainly, workshop will perform:
 General repair
 Cannibalization
 Replacement of part
 Refurbishment
 Limited new manufacture

WORK SCOPE
Regional workshop to attend following jobs:
 Refurbishing / repairing of OCBs &VCBs panel n trolleys of different manufacturers
 Refurbishing / repairing of Isolators &Ring Main Units of various makes
 Centrifuging of isolators n switchgears oil, resulting huge saving of company revenue.
 Repairing of 11kv PTS(Potential Transformer) &CTs
 Repairing of Low Voltage Breaker (420V).
 Painting /coloring of rusty Switch Gears, RMUs body.
 Preparing & paintings of name plates.
 Making of L.T Bus-Bar n L.T clamp as desired & H.T bus-bar for coupling of different manufacturers switches.
 Making of RMU covers , Back Plate n L.T frame support & D.Bs
 Repairing of all test equipments being used in every discipline under GM HT Ops
 Repairing of EFI
 Fabrication and repairing of DB’s / check meter boxes (IBC)
 Repairing of HT/LT poles. (IBC)
WORK FLOW
Regional workshop work flow is defined as follows:

TRAINING
DGM – Work shop to conduct familiarization training on Regional workshop work scope defined as above
with all safety considerations before formation of regional workshop. Training shall be attended by Manager
Workshop and all staff of workshop.

Training will comprise of following:

 Technical training
 Work scope familiarization
 Safety training

Staff required for regional workshop:


 DGM – 1
 Manager– 1
 AE’s /supervisors – 5
 Elect General-1
 Fitter – 2
 Karkun- 5
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 Painter- 1
 Welder- 1
 Masson- 1

ROLES & RESPONSIBILITIES:

DGM- workshop:
 He is overall in charge of regional workshop gangs.
 Collect a weekly report from Manager Workshop and analyze accordingly.
 Submit completion and evaluation outcome to DCDO and Director DS&P.
 Coordinate with GM IBC, DGM, and manager.

Manager- workshop
 Responsible for all activities regarding work shop maintenance.
 Ensure all necessary arrangement are made for material requirement and supervisors are
coordinating accordingly

AE/Supervisors- workshop
 Responsible for overall work in regional workshop.
 Submit consolidated material requirement list.
 Responsible for overall safety measures before start of work.

All other staff- workshop:


 Responsible for all activities regarding maintenance.

MATERIAL MANAGMENT:
Material requisitioning and availability shall be responsibility of respective DGM- regional workshop.
He has to forward consolidate material requirement list to respective Regional Material Coordinator
(RMC’s). The RMC’s shall consolidate their regional demands and forward the same to GM – Material
Management.

SAFETY CONSIDERATIONS:
 Safety action will be clearly out lined in the work plan given by Manager/Supervisor
All relevant safety procedures will be followed in letter
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Section 7 – Preventive Maintenance of 11 KV Feeders


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Purpose of Preventive Maintenance:


Preventive maintenance of feeders is done every year for the management of assets to achieve
the greatest return from the network. The major goal behind the practice of monitoring and
maintaining facilities systems is to provide the best possible services to the consumers in the
most cost-effective manner. Therefore the annual preventive maintenance (APM) plan is aimed
at determination of the optimal balance between preventive and corrective maintenance of the
entire network.

Objectives:
 Improvement of system reliability by minimizing outages / faults and system downtime.
 Decrease cost of corrective maintenance /replacement of damages.
 Reduce accidents by controlling equipment failure)

Scope:
 This SOP shall apply to HT network in all regions of Distribution network.
 This is applicable to the preventive Maintenance of electrical equipment of 11 KV feeders.

Abbreviations:
GM - General Manager
DGM - Deputy General Manager
IM - Inventory Management
FBA - Financial Business Analysis
PM - Preventive Maintenance
HoD - Head of department
SSM - Sub Station Maintenance
UGM - Underground Maintenance
GSM - Grid Station Maintenance
OCB - Oil Circuit Breaker
VCB - Vacuum Circuit Breaker
CT - Current Transformers
PT - Potential Transformers
D/O cut out - Drop Out Cut Out
HRC fuse - High Rupture Capacity fuse
ACSR - Aluminum Conductor Steal Reinforce Conductor
OH -Overhead
EFI -Earth Fault Indicator
DB - Distribution Box
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ROLES & RESPONSIBILITIES


 Dy. Chief –Distribution Officer of Respective Regions are responsible for implementation of
SOP.
 Individual responsibilities of each department for specific activities are described here
after

GM HT
 Overall in charge of project in the region
 Guide Manager PM of region during selection, survey, implementation, monitoring and
evaluation of whole project
 Coordinate with FBA, Procurement and IM to ensure timely availability of PM materials
 Submit completion and evaluation outcome of PM to DCOO and Chief Distribution Officer.
 Coordinate with all GMs HT and share lesson learnt and plan for next year PM

Manager Preventive Maintenance HT


 Select feeders for preventive maintenance as per PM feeder selection criteria.
 Coordinate with Manager SSM, Manager UGM, and Manager IBCs for consolidated survey
and work scope along with material list as per check lists (Annex. “A” & “B”).
 Submit consolidated material list consisting all work scope i.e. S/s, PMT, UG & OH to FBA for
preparation of MR (Annex. “B”).
 Follow up with FBA, Procurement and IM for availability of PM material within specified limit
 Prepare Feeder PM Schedule (Annex. “C”).
 Plan and arrange shutdown of selected feeders including publishing in media (Annex. “D”).
 Coordinate with SSM, UGM, IBCs and operation for availability of manpower, materials,
tools, PPE/SPE and MTLs/special equipments etc prior to work commencement.
 Monitor the entire implementation process to ensure quality.
 Submit “Daily Activity / Slippage form Report” along with material consumption (As per
available format at HT – Distribution).
 Evaluate PM feeders on monthly basis through consolidated fault data submitted by
operation, SSM, UGM & V/IBC.

Manager PM V/IBC
 Conduct survey of selected feeders along with SSM, UGM & Manager PM HT for OH
portion of feeders as per check list and prepare material list and submit to Manager PM HT
 Arrange and store PM OH materials as per timelines
 Arrange manpower, tools & PPE, MTLs as per timelines
 Dispatch gangs with proper supervision for execution of OH work in coordination with
Manager PM HT.
 Closely monitor OH implementation part to ensure quality
 Submit completion report along with material consumption to Manager PM HT
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 Compile data of OH faults on that feeder and submit to Manager PM HT on monthly basis
for PM evaluation

Manager SSM
 Conduct survey of selected feeders along with IBC, UGM & Manager PM HT for S/S & PMTs
of feeders as per check list and prepare material list and submit to Manager PM HT
 Arrange and store PM SSM materials as per timelines
 Arrange manpower, tools & PPE, MTLs as per timelines
 Dispatch gangs with proper supervision for execution of SSM work in coordination with
Manager PM HT.
 Closely monitor SSM implementation part to ensure quality
 Submit completion report along with material consumption to Manager PM HT
 Compile data of SSM faults on that feeder and submit to Manager PM HT on monthly basis
for PM evaluation

Manager UGM
 Conduct survey of selected feeders along with IBC, SSM & Manager PM HT for UG work in
S/S & PMTs of feeders as per check list and prepare material list and submit to Manager
PM HT
 Arrange and store PM UGM materials as per timelines
 Arrange manpower, tools & PPE, MTLs as per timelines
 Dispatch gangs with proper supervision for execution of UGM work in coordination with
Manager PM HT.
 Closely monitor UGM implementation part to ensure quality
 Submit completion report along with material consumption to Manager PM HT
 Compile data of UGM faults on that feeder and submit to Manager PM HT on monthly
basis for PM evaluation

Selection Criteria of Feeders for PM:-


a) Selection of feeders for preventive maintenance work is basic responsibility of GM HT and
Manager Preventive Maintenance HT concerned 11kv Operation department of the region
on the basis of having history/ data of relevant feeders tripping/ fault, duration of tripping,
losses and billing recovery (status besides other relevant consumer data / strategic issue if
any.
b) Tripping and fault records of previous fiscal year including rain and GSM issues should be
considered while selecting feeders for PM.

Planning / Scheduling of Preventive Maintenance


a) After selection of feeders for PM, proper PM plan, including material / man power
requirements and schedule to be prepared by concerned Operation department in
consultation with Sub-station maintenance, UGM and relevant M&C Network.
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Process Description & Interfaces


Responsibility
S.No. Action Items May June July Aug Sept Oct Nov Dec Jan Feb March April
Dept Action by
The selection of feeders for PM will be decided by
Manager PM GM
1 HT Operation team as per selection criteria HT Operation
HT
mentioned in section 6.
The pre- preventive maintenance survey will be HT Operation /
Manager PM / SSM
2 carried out of selected PM feeders & finalize the SSM / UGM /
/ UGM / IBC / VIBC
scope of work. VIBC/IBC
Prepare the material requirement list for HT Ops / SSM / Manager PM / SSM
3
rehabilitation of selected PM feeders UGM / VIBC/IBC / UGM / IBC / VIBC
GM HT / Manager
Ensure availability of required Material which HT Ops / FBA /
PM / GM – FBA /
4 prepared by SSM/UGM/VIBC/IBC for PM of selected IM /
GM - IM / GM
feeders Procurement
Procurement
The P.M. schedule sheet will be made as per the
Manager PM /
5 identified feeders above which will starts from the HT Operation
GM - HT
Month of November & end up to March.
HT Ops / SSM / Manager PM /
6 Execution of PM work on selected Feeders
UGM / VIBC/IBC GM - HT
The PM Evaluation checklist will be filled up after SSM /UGM / AM / Team In
7
completing Preventive maintenance. VIBC / IBC charges
In case of any schedule getting delayed due to any HT Operation /
8 reasons or preventive action if not carried out, SSM /UGM / Manager PM
should be recorded in the P.M slippage record. VIBC / IBC
HT Operation /
Review the P.M. slippage record fortnightly & re Manager PM /
9 SSM /UGM /
schedule the slippage work GM - HT
VIBC / IBC
For the rehabilitation of transformer, Switchgears &
Assistant Engineer
10 other equipment, follow the respective work SSM
/ supervisor
instruction and fill the PM check list.
Operation of Oil / Vacuum Circuit breaker, isolators Assistant Engineer
11 SSM
and power changeover done as per work instruction. / supervisor
Review the P.M. schedule for types of checks & GM – HT /
12 HT Operation
frequency on the basis of its effectiveness. Manager PM
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Scope of Work
The scope of work comprises of the activities that are split between the GSM/ Protection, HT
operations and M&C (LT Network) as stated below.

IBC / VIBC
 Cleaning of excessive deposits of dust on 11 KV insulators.
 Replacement of broken, chipped or tilted insulators.
 Cleaning of rust/moisture on insulators and greasing.
 Renewal of Jumpers- with line taps wherever necessary
 Re-sagging/replacement of worn out/multiple joint conductors.
 Repair/replacement of PMT bus bars.
 Proper jumpering at PMT bus bar with line tape upto D.O cutout.
 Replacement/reinforcement of mix and under size conductors.
 Tree Pruning
 Pole Painting
 Repair of Pole bases
 Completion of Earth conductor.
 Repair of Pole earthing.
 Providing additional HT shackle point if required for operational flexibility.
 Erecting of new HT poles to reduce length of span where required.
 Providing missing double earth wire with Aluminum (ACSR) conductor.
 Providing guard wire at road/railway crossing.
 Providing pole bases where required.
 Check and tight loose nut and bolts of HTT brackets and clamps.
 Providing additional brackets to maintain clearances from buildings/Houses etc.
 Completion of Pole stay / strud jobs
 Replacement of HRC fuses in PMT DBs wherever required
 Repairing / replacement of DB to overhead LT leads.
 Replacement of HRC fuses in PMT DBs wherever required.
 Repairing / replacement of PMT to breaker/breaker to DB/ DB to overhead LT leads with lugs.
 Providing platform at PMTs where required.

SSM/UGM
 Redressing of HT cable leads/cable ends at PMT and SS UGM
 Alignment of HT cables at Switches and Panels in substations and RMU. UGM
 Redressing and alignment of LT cables UGM
 Visible HT/LT UGM cable loops should be properly buried UGM
 Cleaning of HT/LT cable trenches with proper sealing of cable entrance points. UGM
 Pump out water from cable trenches in S/S UGM/SSM
 Tagging on HT cable to verify the location of cable route. UGM
 HT/LT cables proper clamping at switches/panel. UGM
 Cleaning and white wash of substations. SSM
 Painting of switches name in front/back of HT panel SSM
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 Painting of S/S name at front wall of S/S SSM


 Civil Repair work (floor, roof, ventilator, trenches, door etc) if required. SSM
 Cleaning and greasing of male female contacts. SSM
 Check and repair/replacement of LT Panel(s). SSM
 Overhauling of 11KV oil type isolators. SSM
 Maintenance/replacement of D.O cutout with providing proper sizes HT fuses. SSM
 Repair/replacement of HT cambric lead SSM
 Maintenance of CTs, PTs, shrouds and insulators in Switches at substations. SSM
 Fixing of back/side and top Plates wherever missing. SSM
 Maintenance of Base/Grip, LT bus-bars at LT Panel at substation. SSM
 Repair of oil leakage in distribution Transf. and switches at substations. SSM
 Replacement / topping of oil in OCBs and Isolators. SSM
 Replacement of Silica Jell in Transformers. SSM
 Repair of HT and LT leads at dist. Transformers at Pole as well at substations. SSM
 Installation/ replacement of LT Breakers. SSM
 Provision of slabs on trenches in Sub-station SSM
 Door Painting SSM
 Cleaning/removal of nests from PMTs/DB/Breaker/check meter. SSM
 Painting of PMTs/local transformers in S/S and 11KV switches/insulators SSM
 Earthing of 11KV switches and transformers and LT panel SSM
 Provision of wooden cleats from LT panel to transformer SSM
 Cleaning and maintenance of the Knife switches SSM
 Checking and replacement of faulty Capacitor banks. SSM
 Maintenance of EFI. SSM
 Providing PMT name plate with feeder and PMT codes where required. SSM

1. Planning for material for PM


a) After finalization of feeders list with feeder/sub-station/PMT names, a material list should
be prepared by Operation, Sub-station maintenance, UGM and relevant IBC / VIBC network
department, finalized and made available before start of the schedule.

b) Material / inventory position must be updated on weekly basis with start of PM – as to


ensure smooth / timely provision of material as due to lack of some items may result in
delay / incomplete PM work.

2. Process Monitoring
S. No. Description Frequency Responsibility
1 Review of P.M. schedule. Fortnightly Operation / SSM /UGM / VIBC / IBC
2 Review P.M. slippage record. Daily Operation / SSM /UGM / VIBC / IBC
Final Review of PM
3 Annually FBA / IM / Procurement / Corp. HSEQ
effectiveness
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Section A – Annexure
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ANNEX – ‘A’ - Material List

S. No. Items Per Unit

Bare stranded copper


i) 8 (s/s)
1 conductor 3/O SWG KG
ii) 6 (PMT)
(70 mm²)) iii) 5 (single pole)

2 Copper lugs (70 mm²) Max 4 EA

3 G.I. bolt 1x1/2x1/2 mm 2 EA

Brass nut & bolt


4 + EA
1x1/2x1/2 mm

5 Copper plate 1 EA

6 Cement 2 Bag

7 Sand, Shingle, Crush 1 Job

Lime: Salt: Coal


8 1 Job
1:2:3

9 Water & crude oil 1 Job

10 PVC Pipe (3/4 Inch) 24 Feet

11 ¾" PVC Bend 02 EA

12 PVC Bend (U Type) 01 EA

13 PG clamp 1 EA
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ANNEX – ‘B’
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ANNEX – ‘C’
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ANNEX – ‘D’
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ANNEX – ‘E’
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ANNEX – ‘F’
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ANNEX – ‘G’
Earth wire 8 SWG bare copper
Earth conductor (HDBC)

R
Y
B
SL
NE

Garud
wire 8
SWG
HDBC

FILLING
MATERIAL
LIME, SALT
21
AND COAL
FE FILLING WITH RATIO
ET
MATERIAL Earth 1: 2: 3
LIME, SALT
AND COAL
LESS THAN 1 OHM

COPPER 3/O

LESS THAN 1 OHM


WITH RATIO R CONDUCTOR
1: 2: 3

COPPER 3O
CONDUCTOR
Y
COPPER PLATE
COPPER PLATE 4" X 4" X 3"/8
4" X 4" X 3"/8
B

LT STEEL TUBULAR POLE GROUNDING


SL WITH SINGLE EARTH WIRE 8 SWG
HDBC
NE

Reel Insulator
KARACHI ELECTRIC SUPPLY
SCOPE OF CONTRACTOR: COMPANY LTD – KESC
 BORING UPTO 21 FEET OF 5" DIAMETER.
 SUPPLY OF LABOURAR FOR EXCAVATION AND CONCRETE
DISTRIBUTION DEPARTMENT
WORK.
 FILLING BORE WITH LIME, SALT AND COAL. R&D
FOLLOWING WORK IS TO BE CARRIED OUT BY SUB STATION
MAINTENANCE AFTER COMPLETION OF EARTHING UNIT SYSTEM PROVISION OF EARTH CONDUCTOR WITH
JOB.
GUARD IN B/W EARTH & NEUTRAL OF 8 SWG
1 CONNECTION OF D.O. CUTOUT WITH GROUND TERMINAL. HDBC WIRE ON TUBULAR LT POLES
2 CONNECTION OF PMT NEUTRAL WITH GROUND TERMINAL.

Dated: Dwg. No. K/R&D/


Rev 00
November, 2012 HTPG/02/2012
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ANNEX – ‘H’
Earth wire 8 SWG bare copper
Earth conductor (HDBC)

R
Y
B
SL
NE
Garud
wire 8
SWG
HDBC

FILLING
MATERIAL
LIME, SALT
21
AND COAL
FE FILLING WITH RATIO
ET
MATERIAL Earth 1: 2: 3
LIME, SALT
AND COAL
LESS THAN 1 OHM

COPPER 3/O

LESS THAN 1 OHM


WITH RATIO
CONDUCTOR
1: 2: 3 R
COPPER 3/O
CONDUCTOR
Y COPPER PLATE
COPPER PLATE 4" X 4" X 3"/8
4" X 4" X 3"/8
B
LT LATTICE POLE GROUNDING
SL WITH SINGLE EARTH WIRE 8 SWG
HDBC
NE

Reel Insulator
KARACHI ELECTRIC SUPPLY
SCOPE OF CONTRACTOR: COMPANY LTD – KESC
 BORING UPTO 21 FEET OF 5" DIAMETER.
 SUPPLY OF LABOURAR FOR EXCAVATION AND CONCRETE DISTRIBUTION DEPARTMENT
WORK.
 FILLING BORE WITH LIME, SALT AND COAL. R&D
FOLLOWING WORK IS TO BE CARRIED OUT BY SUB STATION
MAINTENANCE AFTER COMPLETION OF EARTHING UNIT SYSTEM JOB. PROVISION OF EARTH CONDUCTOR WITH
1 CONNECTION OF D.O. CUTOUT WITH GROUND TERMINAL.
GUARD IN B/W EARTH & NEUTRAL OF 8 SWG
2 CONNECTION OF PMT NEUTRAL WITH GROUND TERMINAL. HDBC WIRE ON LATTICE LT POLES
Dated: Dwg. No. K/R&D/
Rev 00
November 2012 HTPG/02/2012
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ANNEX – ‘I’

IRON
D

BOL
T
12
MM

Guard wire 8
SWG HDBC
Double Earth
21 FILLING
wire 8 SWG FE MATERIAL
HDBC
ET LIME, SALT
AND COAL
WITH RATIO
1: 2: 3
LESS THAN 1 OHM
R Y B COPPER
3/O
CONDUCT
BOL E1 E2
OR
T
12
MM COPPER PLATE
NUT & BOLT 2½ X 4" X 4" X 3"/8
½ FOR HOLDING NUT &
21 EARTH COND
BOLT
FE FILLING MATERIAL 2½ X ½
ET LIME, SALT AND COAL ADDITIO CROSS ARM
WITH RATION NAL 6' X 3" X 1.5"
3"
1: 2: 3 HOLE
½” DIA
LESS
THAN 1
OHM COPPER 3/O
CONDUCTOR

COPPER
GUARD
HT LATTICE POLE GROUNDING
PLATE
5 4" X 4" X 3"/8
WIRE 8
SWG
WITH DOUBLE EARTH WIRE 8 SWG
INCHES HDBC HDBC

SCOPE OF CONTRACTOR:
KARACHI ELECTRIC SUPPLY
 BORING UPTO 21 FEET OF 5" DIAMETER.
COMPANY LTD – KESC
 SUPPLY OF LABOURAR FOR EXCAVATION AND CONCRETE
WORK.
 FILLING BORE WITH LIME, SALT AND COAL. DISTRIBUTION DEPARTMENT
FOLLOWING WORK IS TO BE CARRIED OUT BY SUB STATION R&D
MAINTENANCE AFTER COMPLETION OF EARTHING UNIT SYSTEM
JOB.
PROVISION OF DOUBLE EARTH CONDUCTOR
1 CONNECTION OF D.O. CUTOUT WITH GROUND TERMINAL.
2 CONNECTION OF PMT NEUTRAL WITH GROUND TERMINAL.
ON HT LATTICE POLES STRUCTURE OF 8 SWG
3 THREE NOS. GAURDS TO BE PROVIDED PER SPAN IN B/W ALONG WITH GUARD WIRES
- DOUBLE EARTH WIRE

00
Dated: Dwg. No. K/R&D/
Rev
November, 2012 HTPG/01/2012
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ANNEX -‘J’

P C

Soil
DEPTH
300-500 mm

Earthing System
Under Test E Current
Probe

Potential
Probe

C1 P1 P2 C2

EARTH
TESTER

Test Set Up for Earth Resistance Measurements


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ANNEX -‘K’
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ANN -‘L’
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Annexure-A
Cover Sheet

SIP #: ________________

IBC: ________________

Subject: _____________________________________________________________________

Synopsis:

__________________ __________________ __________________

GM IBC GM LT GM HT
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Annexure-B

SIP #: ________________

IBC: ________________

Subject: _____________________________________________________________________

1. [Comment]

(Signature)

(Designation)

2. [Comment]

(Signature)

(Designation)

3. [Comment]
(Signature)

(Designation)

4. [Comment]

(Signature)

(Designation)
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Annexure-C
Certificate

SIP #: ________________

IBC: ________________

Subject: _____________________________________________________________________

It is certified that if the subject proposal is implemented then

1. This proposal will provide relief for the entire residential consumer.
2. It will not cater any new area development or a single consumer.
3. The over loaded PMT will be relieved and the Transformer will be prevented from getting burnt.
4. The ratio of Wire Broken cases will be minimized.
5. This scheme will not cater to the needs of any Industry.
6. After implementation of the scheme the system will improve operationally and commercially.
7. The cost will be drawn from the overall budgetary provision of the year. (not included in case of GOP
funded schemes)

_________________ _________________

Manager NW, IBC ( ) GM IBC ( )


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SIP # : _______________________

IBC : _______________________

Subject:
_________________________________________________
________________

Over Loaded PMT (3 months


data)

Number Check billing


Nature of
PMT KVA Loading No of legal No of illegal of HC meter Losses
S. No Month consumers Units Amount Recovery
Name Rating (amps) connections connections accounts reading (%)
(ord/ind) billed billed
created (units)

1Ø-2Ø-

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Annexure-E

Adjacent PMTs'
Specifications

PMT 1

billing
Number Check
Nature of
PMT KVA Loading No of legal No of illegal of HC meter Losses
S. No Month consumers Units Amount Recovery
Name Rating (amps) connections connections accounts reading (%)
(ord/ind) billed billed
created (units)

1Ø-2Ø-

PMT 2

Number Check billing


Nature of
PMT KVA Loading No of legal No of illegal of HC meter Losses
S. No Month consumers Units Amount Recovery
Name Rating (amps) connections connections accounts reading (%)
(ord/ind) billed billed
created (units)

1Ø-2Ø-

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Annexure-F

SIP # :
_______________________

IBC :
_______________________

Subject:
_________________________________________________________________

Details of Industrial Consumers

Size of
cable
S. Connected Outstanding Dues (as
Account # Consumer # Tariff Sanctioned load through
No Load on date)
which it
is fed

_________________ _________________ _________________

Manager billing DGM IBC GM IBC


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Annexure-G

Budgetary Allocation Certificate for System Improvement Schemes

SIP No: ____________

IBC: ____________

Subject: ________________________________________________________

Fiscal year –

1. Total Budget Allocated for SIPs (Region I, II, III & IV) Rs___________
2. No of schemes (SIPs) already approved wit the cost of Rs___________
3. No of schemes (SIPs) executed with the cost of Rs___________
4. Cost of New scheme (SIP) No.______________ Dated _________ Rs___________
5. Balance budget for System Improvement Proposals Rs___________

GM Finance Region DCOO Office ________________________


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Section B SSM Annexures


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MINIMUM CLEARANCES AND DEPTHS FOR SINGLE HT CABLE


LAID IN TRENCH ( measure in mm )

500 mm

1000 mm

200 mm

300 mm

500 mm

LEGEND

COMPACTED BACK FILL

FINE SAND

CABLE WARNING TAPE

CABLE WARNING TILE

HT CABLE

KARACHI ELECTRIC SUPPLY COMPANY– KESC

Distribution Department TPRE

SINGLE HT UG CABLE LAID IN TRENCH

Rev : 00 DRG No 1: K / D /TPRE/SOP/


Dated : 20 /09 /13
CABLE LAYING ..2013
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Form A:

To be filled by SSM

Reaching at Site Work Starting Work Completion


Dispatch Time Total Time Taken
Time Time Time
(A) (D-A)
(B) (C) (D)

Form B:
To be filled by SSM

Rating LT Breaker Make Loadin


Make Rating New PMT
(Ampere Loading Declared g
S. Name Feede (New (Amper Installed
(Existing s) (Existing Faulty (New
No of r LT es)
LT (Existing LT LT
. PMT Name Dat Tim Breake (New Dat Tim
Breaker) LT Breaker) Break
e e r) PMT) e e
Breaker) er)
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Form A:

To be filled by SSM

Reaching at Site Work Starting Work Completion


Dispatch Time Total Time Taken
Time Time Time
(A) (D-A)
(B) (C) (D)

Form A:

To be filled by SSM

Reaching at Site Work Starting Work Completion


Dispatch Time Total Time Taken
Time Time Time
(A) (D-A)
(B) (C) (D)
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Maintenance Request Form (MRF)


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Annex “B” Reconstruction of Substation – 60 Days


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Annex “C” Handing/ Taking Over Certificate

HANDING / TAKING OVER CERTIFICATE

1. Name of Work: ___________________________________________________________________________

2 Agreement No. _______________________. 3. Contractor’s name: M/s ____________________

4. Date of start: ________________________ 5. Date of completion _________________________

The subject job has been completed satisfactorily by the contractor for the above mentioned agreement:

__________________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________________

_____________________________________________________________________________________________________________

__________________ __________________ __________________


Contractor for, Works Department for, User department
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Section C Annexure
12.1 Annexure “A” - Feeder Survey Checklist

FEEDER NAME GRID NAME


SUB STATION WORKS
SR.# ACTIVITIES S/S-A S/S-B S/S-C
No of rooms 3 1 1
Capacity of transformer …..KVA ……KVA ……KVA
No of HT Switches ---- --- ---
Work Required
1 Cleaning & Painting Yes/No Yes/No Yes/No
2 Trench Cover Yes/No Yes/No Yes/No
3 Sub Station Flour / Roof Works Yes/No Yes/No Yes/No
4 Substation Lighting Work Yes/No Yes/No Yes/No
5 Ventilation / Exhaust fan Yes/No Yes/No Yes/No
6 Equipment / Item Tagging Yes/No Yes/No Yes/No
7 Switchgear Maintenance Yes/No Yes/No Yes/No
8 Protection for Overhead HT circuit in substation Yes/No Yes/No Yes/No
9 Installation of EFI Yes/No Yes/No Yes/No
10 Transformer Maintenance Yes/No Yes/No Yes/No
11 Protection for local transformer Yes/No Yes/No Yes/No
12 HT Cable Dressing Yes/No Yes/No Yes/No
13 LT Cable Dressing Yes/No Yes/No Yes/No
14 Replacement of Existing LT Panel with new LT Panel Yes/No Yes/No Yes/No
15 Cable Tray Installation from Transformer to LT Panel Yes/No Yes/No Yes/No
16 LT Panel Maintenance Yes/No Yes/No Yes/No
17 Base Grip and LT Fuses Yes/No Yes/No Yes/No
18 Installation of Check Meter Yes/No Yes/No Yes/No
19 Earthling of S/S to be check to be check to be check
20 Lock Yes/No Yes/No Yes/No
21 Repairing of Door Yes/No Yes/No Yes/No
22 Rubber Flour Yes/No Yes/No Yes/No
23 Cable Coding Yes/No Yes/No Yes/No
24 Printing of S/S name Yes/No Yes/No Yes/No

Prepared by Reviewed by Approved by


Name _____________________ _________________ _________________
Designation ________________ _________________ _________________
Date ______________________ _________________ _________________
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FEEDER NAME GRID NAME

PMT WORKS
RESPONSIBILITY PMT-A PMT-B
SR.# ACTIVITIES
Work Required
1 Pole Foundation M&C Yes/No Yes/No
2 Alignment of pole M&C Yes/No Yes/No
3 Coating and Painting of pole and PMT M&C Yes/No Yes/No
4 HT Busbar M&C Yes/No Yes/No
5 HT Jamper (Busbar to D/O cutout)with Line tape M&C Yes/No Yes/No
6 PMT Maintenance (oil filling,Bushing,LT/HT) M&C Yes/No Yes/No
7 PMT Earthing M&C To be Checked To be Checked
8 H.T. Pin and Supporting Insulators (Replace/cleaning ) M&C Yes/No Yes/No
9 PMT structure % Platform M&C Yes/No Yes/No
10 Pole Painting M&C Yes/No Yes/No
11 HT / LT Cable Clamping UGM Yes/No Yes/No
12 H.T. Cable Dressing UGM Yes/No Yes/No
13 L.T Leads Dressing(PMT to Breaker,Breaker to H/O) S/S Yes/No Yes/No
14 Installation of Check meter Meter Dept Yes/No Yes/No
15 Wooden cleat S/S Yes/No Yes/No
16 D/B Mentanance S/S Yes/No Yes/No
17 D/O Cut outs with Fuse S/S Yes/No Yes/No
18 Maintenance of Piller Box S/S Yes/No Yes/No
19 Maintenace of L.T. Breaker S/S Yes/No Yes/No
20 Installation of L.T. Breaker S/S Yes/No Yes/No
21 Name Plate of PMT & Coding S/S Yes/No Yes/No

Prepared by Reviewed by Approved by


Name _____________________ _________________
_________________
Designation ________________ _________________
_________________
Date ______________________ _________________
_________________
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FEEDER NAME GRID NAME

HT MAINS
S. No. ACTIVITIES RESPONSIBILITY MAINS No of Spans

pole #abc-pole#xy top


1 Reinforcement of HT Conductor M&C --
6A/1PMT,P#1(K/S) to p4A/2 PMT
2 Re-Sagging of H.T O/H M&C Yes/No ---
3 H T D/E with Guards M&C Yes/No ---
4 Installation of HT Pole M&C Yes/No ---

5 Installation of Stay Unit M&C Yes/No --


6 Maintenance of HT O/H M&C Yes/No ---
7 HT Cable Maintenance M&C Yes/No ----

8 HT Cable Termination M&C Yes/No ----

9 HT Pole Earthing M&C Yes/No ----

10 Cleaning of Insulators M&C Yes/No ----

11 Pole Base M&C Yes/No ----


12 Pole Painting M&C Yes/No -----

Prepared by Reviewed by Approved by


Name _____________________ _________________ _________________
Designation ________________ _________________ _________________
Date ______________________ _________________ _________________
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12.2 Annexure “B” - Material Requirement List

Material Requirement – Substation (Sample List)


Quantity Total
S.No Work involved Material Requirement No. of units(SS)
Required/unit Quantity
Cleaning of S/S & Switch Cotton Waste - -
1 -
Gear Cleaning Kerosene Oil - -
2 Trench Cover Slabs - - -
Sub station Floor/Roof
3 To be consulted by Real Estate Deptt
Work
4 Ventilation/Exhaust fan Exhaust Fans - - -
Protection of OH HT &
5 Protection Relays To be consulted by Substation Protection Deptt
Local Transformer
6 Installation of EFIs EFI - - -
7 HT Cable Alignment YES/NO
8 LT Cable Alignment YES/NO
Installation of Wooden
9 Wooden Cleats YES/NO
Cleats
10 Repairing of doors YES/NO

Material Requirement - PMT WORKS (Sample List)


No. of
Quantity Total
S.No Work involved Material Requirement units(Poles or
Required/unit Quantity
spans)
Reinforcement of HT
1 Copper Wire(2SWG to 3-0) - - -
Conductor
Aluminium Goffer for
2 H T D/E with Guards - - -
Double Earth
HT pole
Channel Iron Bracket 14,
5(1/2)
3 Installation of HT Pole - - -
HT phase bracket (5 1/2 ft)
Pin insulators
Steel Pin
Binding Wire
Maintenance of HT O/H &
4 Cotton Waste - - -
Cleaning of insulators
Kerosene Oil
Cement
5 Pole Base - - -
Shingle
Grey paint
6 Pole Painting Orange Paint - - -
Taropin oil
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Material Requirement - OH WORKS (Sample List)


No. of units Quantity Total
S.No Work involved Material Requirement
(PMTs/poles) Required/unit Quantity
Cement - - -
1 Pole Foundation
Shingle - - -
2 HT bus-bar Copper 3-0 HD

3 HT Jumper (Busbar to D/O Line tabs 3-O


cutout)with Line tape
- - -
4 Grey paint
5 Pole Painting Orange Paint
6 Tarpene oil
7 H.T. Cable Clamping Clamp
8 H.T. Cable Dressing Outdoor Termination Kit - - -
9 Wooden cleat Wooden Cleat
10 D/O Cut outs with Fuse D/O set
- - -
11 Installation of L.T. Breaker LT breaker
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12.3 Annexure “C” - Feeder Preventive Maintenance schedule

Time Loop/Portion Work Scope Man power


Feeder
S.NO Date Region IBC/VIBC MTLs
Name OH
From To From To S/S PMTs UGM SSM Mains Opn
Span
09:30 16:30 ABC ABC Pole# 31
1 01.01.2013 I XYZ 3 12 21 2 2 3 1 3
Hrs Hrs Industry S/S RMU

6
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12.4 Annexure “D” - Shut down Request form

Form “ B”

Published
Forced
Request for Availing

Date of required Shutdown _________________________ Availing department


_________________________
Shutdown required for
_______________________________________________________________________
___________________________________________________________________________________
_______
Involving of (220KV / 132KV / 66KV / 0.4KV)
Timing required from ___________________________________ to
__________________________________
Substation / PMTs affected during Shutdown
_____________________________________________________
___________________________________________________________________________________
_______
Work permit may be issued to __________________________ Designation
____________________________
Mr. ____________________ Since LT Main are involved, _________________ Designation
________________
Mr. ____________________ is authorized to make the line / equipment dead for safe working, if
allowed and assigned b System Operation. Any special Remarks
________________________________________________

Date:___________________ Signature of Manager (Requesting


department)

______________________________________
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11-KV-Operation

Permission
The shutdown against the work requested above is permitted with the advice to complete the work
Within stipulated time.

Any special Remarks


_________________________________________________________________________
Operations to carry out:
______________________________________________________________________

Date:___________________ Signature of Manager


Operations

______________________________

Underground Maintenance

Work Sequence

Work required
______________________________________________________________________
Work stated at __________________________ work finished at
______________________________

Date:___________________ Signature of supervisor

______________________________

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Sub-Station Maintenance

Work required
______________________________________________________________________
Work stated at __________________________ work finished at
______________________________

Date:___________________ Signature of supervisor

______________________________

Area Maintenance (MC) / New Connection (Construction)

Work required
______________________________________________________________________
Work stated at __________________________ work finished at
______________________________

Date:___________________ Signature of supervisor

______________________________

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11-KV-Operation

Monitoring

Shutdown arranged at ______________________ If delayed, Reason


__________________________
____________________________________________________________________________
______

Shutdown normalized at ____________________ If delayed, Reason


__________________________
____________________________________________________________________________
______

Date:___________________ Signature of supervisor

______________________________

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