UNLOADING, STORAGE, ERECTION,

INSTALLATION & MAINTENANCE MANUAL

420 kV MAINTENANCE EARTH SWITCH

TYPE: FEE(MES)

Page 1 of 30
Disconnectors are remarkable pieces of equipment.
They can stay in the same position for years before they
have to switch. But, then at the critical moment they
have to work perfectly. No matter what the condition
are, whether they are in the freezing cold or in the
extreme hot.

Page 2 of 30
 INDEX
1.0. PREAMBLE 5
2.0. GENERAL DESCRIPTION OF THE MAINTENANCE EARTH SWITCH 5

SECTION: A UNLOADING AND STORAGE INSTRUCTIONS

3.0. UNLOADING 6
3.1. STORAGE 6
3.2. LONG TERM STORAGE INSTRUCTIONS 6

SECTION: B CONSTRUCTION
4.0. BASE ASSEMBLY 9
5.0. FIXED CONTACT SUPPPORT 9
6.0. OPERATING MECHANISM 10
7.0. DOWN OPERATING PIPE 11
8.0. TANDEM PIPE ASSEMBLY 11
9.0. EARTH SWITCH ASSEMBLY. TYPE- DIRECT ENTRY (DEE) 12
10.0. EARTH FIXED CONTACT ASSEMBLY 13
11.0. INSULATOR ASSEMBLY 13
12.0. SUPPORT STRUCTURE 13

SECTION: C INSTALLATION & SETTING INSTRUCTION

13.0. STRUCTURE 14
14.0. BASE ASSEMBLY 14
15.0. INSULATORS 15
16.0. FIXED CONTACT ASSEMBLY 16
17.0. EARTH SWITCH ASSEMBLY 18
18.0. OPERATING MECHANISM AND DOWN OPERATING PIPE 19
19.0. TANDEM PIPE ASSEMBLY 24

Page 3 of 30
SECTION: D COMMISIONING AND MAINTENANCE

20.0. COMMISIONING OF MAINTENANCE EARTH SWITCH 25

21.0. MAINTENANCE 25
22.0. TOOLS AND TACKLES 25
23.0. RECOMMENDED SPARES 26
24.0. RECYCLING OF END OF PRODUCT LIFE MATERIAL AND DISPOSAL 27

DOCUMENTS ATTACHED

LIMIT SWITCH AND AUXLIARY SWITCH SETTING PROCEDURE

O&M INSPECTION PROCEDURE

DISCONNECTOR SITE SETUP / CHECK PROCEDURE

Page 4 of 30
1.0. PREAMBLE:

The maintenance earth switch described in this publication is designed, manufactured and tested with
care and will give satisfactory service if it is installed, operated and maintained in accordance with the
instructions, by fully skilled personnel duly authorized to carry out this work.
Efforts are constantly being made to improve design and manufacturing. Hence the equipment
supplied may differ in minor detail from the data given in this publication.

2.0 GENERAL DESCRIPTION OF THE MAINTENANCE EARTH SWITCH:

 Maintenance earth switch are used to connect the live parts/line conductors and discharge the voltage
to earth, during maintenance and testing.

 420 kV maintenance earth switch are designed for independent single pole operation or three
pole mechanically ganged operation. It can be operated either manually or by motor.

 420 kV maintenance earth switch are checked for satisfactory operation at the works. They are
supplied in knock down condition ready for assembly at site. The relevant standards for maintenance
earth switch are IEC: 62271-102 and IS: 9921. For insulators IEC: 60273 / 60168 and IS: 2544.

Page 5 of 30
 SECTION-A

UNLOADING AND STROAGE INSTRUCTIONS

3.0 UNLOADING:

 Unload the crates / boxes using crane / fork lift truck, as appropriate.
 Do not roll the crates. Do not drop the crates over tyres / rubber mats. Etc.
 Use proper lifting tools / tackles like nylon belts / ropes etc.
 Count the number of crates / boxes and tally them against the shipping document.
 Inspect thoroughly all the crates / boxes for damages.
 In case of damage, identify the crate / box and keep it separately.
 Take adequate photos of the damage.
 Kindly report the damage to the transporter in writing.
 Also mail the damage report (along with the photographs) to Mr. S.R. Kumaresh of S&S Power
Switchgear Equipment Limited. Email: srk@sspower.com.
 Segregate the crates, voltage rating wise. Colour codes are provided in individual crate / box for each
voltage rating.
(White – 36kV, Yellow – 145kV, Green – 245kV & Blue – 420kV)

3.1 STORAGE:

“Failure to properly store and protect disconnectors / parts may cause damage to
equipment. Such damage could cause hard operation, mal-operation and contact resistance
issue when equipment is installed / tested and mal-function in service.”

 Storage shall be made in an area that is well ventilated and provided with drains to prevent water
stagnation.
 It is advisable to leave all crates / boxes in packed condition until the start of erection.
 All crates / boxes shall be properly stored / stacked with proper covers.
 Disconnector and operating mechanism crates / boxes should always be stored in elevated position
(at least two feet above ground) to prevent water entry.
 In case of longer storage period / damp atmosphere, the operating mechanism boxes shall be
removed from packing and electrical space heating is to be provided.
 Space heating should continue till complete removal of moisture / condensation.
 Adequate care to be taken to prevent entry / ingress of dirt, moisture, cement, sand and other
corrosive material.

Page 6 of 30
3.2 LONG TERM STORAGE INSTRUCTIONS:

General instruction (for all materials):

Ground clearance:
All materials, including operating mechanisms, should be kept at a minimum of 600 mm (two feet)
height from the ground level using pallets or cement concrete bed, to avoid water entry during rainy season.
However, the water level rise at the respective site / storage locations shall be considered for fixing the
ground clearance (but shall not be less than 600 mm).

Operating mechanisms:
The primary consideration in case of long term storage of operating mechanism is the
temperature and relative humidity level of the storage location. This should be maintained as closely
as possible to the standard reference atmospheric conditions.

Upon unloading from the container / truck, kindly follow the steps specified below, to ensure proper storage
and preservation of operating mechanisms, for long term storage:

During normal seasons (without rain / snow):

 Take out the operating mechanisms from the wooden cases.
 Remove the polythene cover / bubble wrap sheet carefully.
 Check the operating mechanisms visually for any damages.
 Clean all the outer surfaces.
 Open the door and remove the desiccants (silica gel pack) fitted inside the box.
 Place five fresh bag indicator type desiccant packs (each 100 grams) of fresh silica gel granules
(preservatives).
 Close the door.
 Do not cover or wrap the operating mechanism (so that better breathing is provided during long term
storage).
 In case of longer periods of storage, replace the silica gel once in 3 months and close the door. (Note:
the three month period is indicative only. Kindly check with the supplier of silica gel for time period
of usage and time after when it has to be replaced).
 Ensure that the silica gels used are the fresh ones removed from the air tight container (before placing
them inside the operating mechanism boxes).
 Keep all the drive mechanisms in a dust free environment.
 If dust is unavoidable then ensure complete cleaning at least once in a month.
 In addition carry out periodical checks for any abnormal dust accumulation and clean accordingly.
 Ensure that the entire storage area is temperature controlled (to ensure better storage and condition of
the equipment).
 The optimum temperature is 20 deg c and relative humidity is 45% (values to be checked using
combined humidity and temperature indicators placed throughout the warehouse / storage area and
should be visible for close monitoring).
Page 7 of 30
During monsoon seasons (with rain / snow):
 All points given above shall be followed.
 In addition, during rainy season, anti condensation heaters to be kept “on” and suitable electrical
protection to trip the electrical circuit to be provided in case of any short circuit.
 Foam adhesive backed strip with volatile corrosion inhibitors also to be paste along the inner surfaces
of the operating mechanism in place of silica gels.
 Inspect all operating mechanism boxes for integrity of the painted surfaces once in a month.

Other contacts and steel materials:

 Clean all the contact surfaces thoroughly with a lint-free cloth.
 Protect all contact surfaces with a thin layer of petroleum gel.
 Cover all contacts and aluminium arms with polythene sheets / covers.
 Ensure that the inside surfaces of the polythene coverings are pasted with foam based adhesive strip.
 Provide volatile corrosion inhibitors sheets and paste them along the inner surfaces.
 Kindly repeat the above steps once in every three months.

Galvanized steel items:

These are to be wrapped / covered with waterproof / dust proof covering and sufficient bags of silica
gels to be placed in various places inside the covering. Once in 3 months all materials to be cleaned and
replaced with silica gel bags.

Page 8 of 30
 SECTION – B

CONSTRUCTION

Our 420kV Maintenance earth switch comprises the following:

4.0. Base assembly.
5.0. Fixed contact support.
6.0. Operating mechanism.
7.0. Down operating pipe.
8.0. Tandem pipe assembly.
9.0. Earth switch assembly. Type – Direct Entry (DEE).
10.0. Earth fixed contact assembly.
11.0. Insulators (Optional).
12.0. Support structure (Optional).

4.0. BASE ASSEMBLY:

 Each 3 pole maintenance earth switch (R, Y, B) is supplied with two types of base assemblies.
a) One base Assembly (say R pole) with drive arrangement.
b) Other two bases (i.e. Y&B) without drive arrangement.
 The base consists of a hot-dip-galvanized steel channel (1) (See figure. A).
 All ferrous parts in base assembly are hot-dip galvanized to IS 4759-1984.
 Base assemblies are supplied with:
a) Torque bearing (2) in assembled and aligned condition (only for drive end).
b) Lever and hinges with pins, Friction washer, Brass washers and Split pins.
c) Four holes on plate fixed at base bottom (3) for fixing the base channel to the supporting
structure.
d) One fixed support to hold insulator (4).

5.0. FIXED CONTACT SUPPORT:

 The Aluminium support (5) has provisions to fix the earth fixed contact (6) as well as terminal pad
(7) (See figure. A).

Page 9 of 30
 FIGURE - A

POLE ASSEMBLY
6.0. OPERATING MECHANISM:

 Geared motor operating mechanism consists of a final worm reduction gear driven by a DC or 3Ø
AC motor in line with customer requirements.
 Necessary Overload protection, Control Switches for Local / Manual / Remote operation and Limit
Switches for Control / Signal are provided. In the event of supply failure, the Mechanism can be
operated manually. Manual operating mechanisms are supplied with or without reduction gear in
accordance with customer requirements.
 The Mechanisms are housed in an IP55 grade box made of Aluminium / Mild steel / Stainless steel
having a thickness of 2-3mm. Auxiliary switches having silver-plated contacts with positive wiping
action with adequate number of NO, NC and long wipe contacts as per specific requirements are
provided. Suitable blank gland plate is provided at the bottom for cable terminal gland.
 Suitable terminal blocks made of non-inflammable thermosetting plastic are provided for terminating
control and auxiliary wiring. Front door of the mechanism box is provided with good quality gasket
to ensure high degree of protection against polluted atmosphere. (See figure. B)

Page 10 of 30
7.0. DOWN OPERATING PIPE:

 This assembly is used to connect the ‘T’ Bar torque bearing assembly fitted in base assembly to the
flange fitted in operating mechanism box assembly.
(See figure. C).
 The above assemblies are made out of MS Pipe with ‘T’ Bar Welded in topside and vernier flange-
welded at the bottom according to structure height.
 The above welded Assembly is hot dip galvanized.
 Depending on customer requirement universal joints can be provided as follows.
a) Two Universal joint (1), one with ‘T’ Bar (2) and other on the vernier flange (3) of the drive
mechanism.
b) One Universal joint at the bottom and diaphragm plate (4) on the top.

8.0. TANDEM PIPE ASSEMBLY:

 The tandem pipe assembly is used to connect adjacent poles for gang operation of all the three poles
with one drive mechanism. The lengths are adjustable to suit minor variation at site. (See figure. D)
 These parts are hot-dip galvanized and assembled with necessary pins & bushes etc.

FIGURE – B FIGURE - C

DRIVE BOX

DOWN OPERATING PIPE

Page 11 of 30
 FIGURE - D

TANDEM/GANG PIPE
9.0. EARTH SWITCH ASSEMBLY. TYPE- DIRECT ENTRY (DEE):

 Direct Entry Earth Switch is operated through levers (1) and has over center provision to prevent the
switch from opening due to wind forces, vibrations or any short circuit force. (See figure. E)
 Extrusion contacts (3) which is made out of electrolytic copper with silver plating are fixed to end of
the moving Blade made out of Aluminium tube (2).
 Mounting Plate and all other parts are Hot-Dip Galvanized and supplied in assembled condition.
 The lower end of the tube is provided with flexible tinned copper connector (4) (number and size
according to the short-circuit withstand capability) for the connection to the earthing switch base.
 Hook (5) is provided in the tube to hold the fixed screw in earth fixed contact by turn and twist
mechanism to safeguard accidental opening of earth blade from short circuit force, wind force etc.,

FIGURE – E

Page 12 of 30
10.0. EARTH FIXED CONTACT ASSEMBLY:

 The fixed contacts are of the multi-finger reverse-loop pattern (1). Contact pressure is applied to each
individual finger by an insulated stainless steel spring (2). Contact fingers are of hard
drawn copper, silver plated and are bolted into the aluminum alloy support casting (3). (See figure.
F).
 Electrolytic corrosion between the fingers and aluminium alloy is inhibited by doing tin plating at the
bottom side (contact surface with aluminium casting) of finger and also application of electrical
jointing compound during assembly.

FIGURE – F

11.0. INSULATOR ASSEMBLY:

 Insulators (8) are selected to meet the basic insulation level, minimum creepage and minimum
bending load to suit the Customer / Design requirement. (See figure. A).

12.0. SUPPORT STRUCTURE:

 Support structure, when ordered, shall be designed and manufactured to meet customer
specifications. They are assembled on the civil foundations of the customer and shall meet the
dimensions of the maintenance earth switch with their respective drives etc.
 Structures are hot dip galvanized to meet IS4759 – 1984 Specifications.
 Structures are designed with necessary factor of safety to withstand all forces i.e., short
circuit force, wind force and dead load etc.

Page 13 of 30
 SECTION – C

INSTALLATION & SETTING INSTRUCTION

Warning: Earth Switches are high voltage equipment. In all the site safety precautions and
requirements shall be strictly followed. The line where the Earth Switch is to be connected should be
de- energized before commencing of the work.

13.0. STRUCTURE: (WHERE SCOPE IS INCLUDED)

 Refer the site layout and identify the structures of the respective maintenance earth switch to meet the
sub-station lay-out.
 Assemble the members on their respective foundations as per their general layout.
 Complete the assembly and tighten all the bolts with nuts, washers etc.
 Check for levels at the top of the Structure in the both directions by using spirit level / Water levels.
If required give shims below the base plate of structure and tighten the nuts.
 Similarly complete erection of all structures.
 After erection, check for the following:
a) All fixing dimensions with respect to the centre of the structure.
b) Diagonal distance to match as per contract drawing.

14.0. BASE ASSEMBLY:

 Identify the base drive & non drive end.

 Remove the base fixing hardware from bases and keep it in proper place.
 Lift the base assembly and keep it on a leveled platform.
 Identify the drive end base and place in the proper position on top of the structure. Fix the hardware;
do not tighten fully.
 Place the other two bases on top of the structure in the proper position. Fix the hardware; do not
tighten fully.
 Check with sprit level on top of bearing shaft (See figure. G) and give shims if required on the leg of
the bases.
 Check the diagonal distances.
 Tighten all the bolts. After complete tightening once again check with sprit level.

Note:
 Ensure the correctness of centre line of same pole and centre line of other phases.

Page 14 of 30
 FIGURE – G

STRUCTURE (TYPICAL)

15.0. INSULATORS:

Before Start of erection

 Clean the insulator thoroughly.
 Keep the fixing hardware in respective places.
 Identify the Insulator and keep them in respective position.

ERECTION
 Lift the insulator by using proper Cloth / Nylon sling and place it over the base assembly (Middle).
(Ensure top 4 holes of insulator are parallel to base center line).
 Without removing the sling match the bottom fixing holes and fix all bolts.
 Remove the sling and check for level of the top surface of insulator by sprit level / plumb (See
figure. H).
 If necessary add shims below the bottom flange of the insulator.

Page 15 of 30
16.0. FIXED CONTACT ASSEMBLY:

 Identify the fixed contact support (1) and direction to fix the earth fixed contact assembly through
contracts general assembly drawing (See figure. I).
 Take the terminal pad (2), earth fixed contact assembly (3) and fix it with fixed contact support by
using M12 bolts and nuts.
 Lift the fixed contact assembly with support and place it over the insulator as per the general
assembly drawing and tight the bolts.
 Repeat the same for the other two poles.

FIGURE – H

ERECTION OF INSULATOR ASSEMBLY

Page 16 of 30
 FIGURE – I

MOUNTING OF FIXED CONTACT

Page 17 of 30
17.0. EARTH SWITCH ASSEMBLY:

 Identify the drive & non-drive earth switch and fixing side of the earth switch by referring to the
general arrangement drawings.
 Lift the earth switch assembly by using rope and fix it with base assembly by using M12 bolts and
nuts.
 Operate the Earth Switch by using lever (1) and check for the alignment. (See figure J).
 If the centre line of the moving blade (2) and fixed contact is not straight adjust the moving blade
assembly by using necessary shims.
 Tighten all Bolts.
 Repeat the above procedure on the other two poles.
 Induced current contacts (if fitted) should be checked for proper operation. Upon closing the earth
switch, the induced current contact should touch the insulated lever on the groove. If not adjust the
induced current contact fixing by unlocking the nut and moving it on the earth switch tube.

Caution: The alignment of the Earth Switch should be checked after cables and bus bars have
been connected.

FIGURE – J

Page 18 of 30
18.0. OPERATING MECHANISM AND DOWN OPERATING PIPE:

Identify the mechanism box with the help of drawing and packing list and open the case
carefully.

MOUNTING:
Do not attempt to lift mechanism by drive coupling flange. Use slings or forklift at base of
cubicle. Lift mechanism box into position and fix with structure. At this stage fixing bolts should only
be hand tightened.
CONNECTING MAINTENANCE EARTH SWITCH:
 Check for centre line and vertical line between torque bearing flange and drive flange with a plumb.
 Fix the tee bar end of the down operating pipe to the universal yoke and fix the assembly to the
provision available on the drive end base (See figure. K).
 Now fix the other end of down operating pipe to the universal yoke and fix the assembly to drive box
flange using the principle of vernier hole alignment (Only two holes will be aligned).
 Tighten all bolts.
 Operate the pole manually and ensure open/close label is in proper position.

ADJUSTMENT:
A. MANUAL
By using handle, operate the maintenance earth switch and observe whether it is OPENS or
CLOSES fully at each end of its operating cycle. (Ensure minimum 10mm gap between
pad lock brackets.) If the maintenance earth switch does not CLOSE fully remove clamping bolts
which is bolted on the operating mechanism flange and turn mechanism slightly towards OPEN and
retighten bolts with the help of vernier flange provided. Proceed with earth switch closing. Repeat
until satisfactory operation is obtained.

B. ELEC TR ICAL
Make electrical connections strictly according to the contract diagram of connections of incoming
supply. Do not attempt to operate the maintenance earth switch under power at this stage.
When selector switch is fitted, set it to LOCAL.
When Motor is fitted, manually set Mechanism to mid Position and: -
 Operate Control Switch and at the same time observe whether the mechanism rotates towards the
selected position.
 If it rotates in opposite direction to that selected, stop motor immediately, by switching off power
supply or by using Emergency push button switch.
 Reverse the connection of motor supply.

Page 19 of 30
EL ECT R IC AL OPERATING EQUIPMENT:
A hinged panel on the left hand or right hand side of the cabinet carries the electrical control, for operation
of the mechanism, which is accessible immediately after the cabinet outer door is
opened.

PANEL DOOR COMPONENTS:

LOCAL / REMOTE / MANUAL SELECTOR SWITCH
This selector switch is provided to select the position according to the requirement.When the selector
switch is set to local, operation of the mechanism will be governed by the controls in the cabinet. Setting
the selector switch to remote transfers controls of the mechanism to remove control point.

OPEN AND CLOSE SWITCH

Incase of individual pole drives, the master control cabinet will have push buttons / selector switch for
opening / closing also. The control switch determines the direction of travel of the maintenance earth
switch. When a cycle is initiated by switching to the appropriate position, the earth switch will open or
close. Once the mechanism receives a signal from the push button/ selector switch, the mechanism will
commence the operation and will not respond to further signals until it has completed its operation. An
indicator is provided outside the top sheet of the cabinet (below the output shaft) to show the earth switch
is OPEN or CLOSE.

HEATER AND THERMOSTAT (OPTIONAL)

An anti-condensation heater is fitted in the cabinet. A switch is mounted on the front of the control panel
for the control of the heater through a thermostat. It should be switched on as and when required to ensure
that appropriate temperature inside the cabinet is maintained. The heated air leaves the cabinet by way of a
breather.

OPEN AND CLOSE CONTACTORS

These contactors are mounted in the rear of the panel door. They directly control the reversing
operation of the motor. Further contacts are used for electrically interlocking the contactors, providing
circuit across the ‘OPEN’ and ‘CLOSE’ Push Buttons / Cam Switch.

AUXILLARY SWITCHES
Auxiliary switch are mounted in the rear side of the cabinet connected to gear shaft through cam and
operating lever. It consist of silver plated contacts with a positive wiping action, which provides low
current signal to control circuit.

TERMINAL BLOCKS
Terminal Blocks are designed for use with 1.5 / 2.5 Sqmm.cable. Rated Miniature circuit Breaker / Fuse
is mounted in the panel door. The current ratings of fuse-links/MCB are shown on the schematic diagram.

Page 20 of 30
FOR CLOSING OPERATION OF MAINTENANCE EARTH SWITCH
Set the selector switch to local execution as required and then operate the cam switch
for closing, there by causing the closing contactor (CC) to pick up. The hold on contact of closing
contactor (CC) will now be closed there by retaining the supply after the cam switch is released.
After completion of closing cycle, when the earth switch operate for opening, the opening
contactor (OC) will pickup. The hold on contact of opening contactor (OC) will now be closed there by
retaining the supply after the cam switch is released. Ensure motor direction is towards closing. Otherwise
change the p hase sequence of motor in terminal box. The earth switch will start to close. At the end of the
closing operation limit switch for closing (LSC) will open, de-energizing the closing contactor (CC).
The circuit is now de-energized and the closing operation is completed.
Kindly note, to prevent mal functioning, contact (CC) of the closing contactor will isolate the
opening circuit, once contactor (CC) is energized.

FOR OPENING THE MAINTENANCE EARTH SWITCH

A Similar sequence of operation will be executed by operating the cam switch in the other direction.

OPERATION OF BOLT COIL (MOTOR / MANUAL)

LMR (Local Manual Remote) switch in local or remote position.

 The plunger is in protruded condition (coil de-energized).
 The cap fixed to the plunger blocks the insertion of the manual handle (there by preventing manual
operation).
 When the MPB switch is pressed, the supply will go to bolt coil and pulls the plunger downwards.
 The plunger inturn actuates the limit switch positioned below the plunger, cutting off the supply to
the motor.
 The manual operating handle can now be inserted & the gear box can be operated manually.

OPERATION OF AUXILARY SWITCH OPERATION / SETTING

CONSTRUCTION – 1
 Auxiliary switch is fixed to the rear sheet of the drive box along with bracket.
 A slotted lever is fixed with the drive shaft (square) of auxiliary switch and clamped with
bolt and nut.
 A cam is fixed with the main shaft (bottom side extended) of the gearbox below the limit
switch cams and locked with screw and nut.
 A link plate is assembled with cam on one side and with auxiliary lever on the other side.

Page 21 of 30
 OPERATION
Whenever the main shaft rotates either to close or open the cam also will rotate and
operates the auxiliary switch through the link.

Note:
The auxiliary switch settings are done at works. However, in case fine tuning is required then
follow the steps given below.

SETTING
 Keep the earth switch in open / closed condition.
 Keep the auxiliary switch lever in ‘NO’ position according to scheme.
 Rotate the cam and check the continuity of required contacts in auxiliary switch.
 If required loosen the pin in auxiliary switch slot and move the pin with in the slot
either inside or outside and lock it again.
 After this adjustment again operate and check for continuity.
 In the same way other positions also can be set.

LIMIT SWITCH OPERATION IN DRIVE MECHANISM

CONSTRUCTION-1
 Limit switch is fixed to a bracket and the entire set is fitted to the rear sheet of the drive box.
 The operating cam is fixed to the main shaft (bottom side extended) of gear box and
locked with screw after positioning the cam.

OPERATION
Whenever the main shaft rotates either in close direction or open direction, the cams fitted
in the main shaft also will rotate and operates the relevant limit switch.

Note:
The limit switch settings are done at works. However, in case fine tuning is required then follow the
steps given below.

SETTING
 Operate the earth switch manually to open position.
 Rotate the cam and press the limit switch roller till it disconnect the contact (a click
sound will be heard).
 Again close the earth switch manually.
 Now operate the earth switch by motor and see that the operation is completed by limit switch.
 If any further small adjustment is required, the cam can be rotated towards roller or away from roller.
 In the same way another switch (for closing) can be set.

Page 22 of 30
FIGURE - K

Page 23 of 30
19.0. TANDEM PIPE ASSEMBLY:

 Remove the connecting pin from the lever and keep it separately.
 Keep the drive pole maintenance earth switch in closed position.
 Keep the second pole in closed position. Connect the tandem pipe (Phase coupling pipe). If required
extend or shorten by adjusting the screw rod.
 Likewise, with the drive pole & second pole in closed condition, keep the third pole also in closed
condition and connect the tandem pipe between the second & the third pole.
 Operate the maintenance earth switch manually and ensure it opens and closes properly. If not, then
adjust the tandem pipe length.
 Ensure all split pins are secured properly. (See figure. L).
 Connect the small push pipe which is with base assembly to be connected with the earth switch lever
assembly as shown in general arrangement drawing.

FIGURE - L

Page 24 of 30
 SECTION – D
COMMISIONING AND MAINTENANCE

20.0. COMMISIONING OF MAINTENANCE EARTH SWITCH:

 Carry out test operation manually; ensure satisfactory engagement of contacts for all three poles. If
necessary, align the contacts.
 Operate the maintenance earth switch by power. Ensure proper open/close operation. Ensure limit
switch / auxiliary switch settings are proper.

21.0. MAINTENANCE:
Caution:
 Working on high-voltage is very dangerous; hence follow substation and other standard safety
rules.
 Don’t use emery paper for cleaning the contacts.
 Don’t try to operate the earth switch when terminal is live.
Do:
 Ensure disconnection of circuits before doing maintenance activity.
 Do proper earthing of the circuit.
 Stay clear of adjacent live parts; wherever possible, earth the adjacent live parts.
 Use proper tools.

We recommend the following inspection intervals

 Normal ambient condition: After every 5 years or after every 1000 operations (Close/open cycle).
 Extreme ambient conditions i.e. Climate (tropical) and heavy contamination (dust, salt, rust and
sulphur): After every 2 years or after every 500 operations (Close/open cycle).

22.0. TOOLS AND TACKLES:

Apart from standard tools, the following are required

 Brass wire brush for cleaning of Copper surfaces.

 Steel wire brush for cleaning for Aluminum and steel surfaces.
 Contact grease (Petroleum jelly).
 Cold cleaning agent for Silver plated surfaces.
 Lint – free cloth.

Page 25 of 30
 Cleaning:
Bolted or sliding contact surfaces that conduct current have an effect on the electrical resistance of
the current path. Dirty or oxidized contact surfaces increase the electrical resistance. This will result in
damage to main contacts. Hence the following cleaning procedure shall be strictly adhered to:
Bolted Contact Surfaces: Aluminum
 Grease lightly.
 With steel wire brush, remove oxide film fully (Do not use emery paper).
 Wipe off contaminated grease immediately using lint – free cloth.
 Re-apply grease again (Immediately after cleaning with lint –free cloth).
 Bolt together treated surfaces and grease joints.

Silver plated contact surfaces.

 Clean with cold cleaning agent (do not destroy silver surfaces).
 Grease immediately.
 Bolt together treated surfaces and grease joints.

Silver plated contact surfaces (Sliding)

 Clean with cold cleaning agent (do not destroy silver surfaces).
 Grease immediately.

Inspection checks:
The following operations must be carried out during inspection
Maintenance earth switch:
 Clean contact area (Male and Female contacts). Check for any damage; if required, change the
contacts.
 Apply grease on contact surfaces.
 Clean the insulators. Check for any damage; if required, change.
 Check all bolted connections.
 Carry out three or four test operations manually.
 Reconnect the power supplies and control voltage.
 Carry our three or four test operations electrically.
 Check the earthing connections between earth blade and base; if required, replace.

23.0. RECOMMENDED SPARES:

Keep adequate quantity of following spares at all times.
 Fixed contact fingers.
 Moving blade extrusion.
 Clevis pins with nylon washers, split pins.
 Control springs.

Page 26 of 30
24.0. RECYCLING OF END OF PRODUCT LIFE MATERIAL AND DISPOSAL

1. Overview

From power transmission and distribution systems, scrap white porcelain-insulators were
collected. These insulators have a high degree of hardness, and low water absorbability. A study
was conducted in the use of crushed porcelain as a ceramics aggregate.

Commercially available ceramics aggregate is used in colored permeable pavement. Such

products are expensive. It is anticipated, however, that the pavement market will expand because
permeable pavement material is useful for: (1) alleviating the so-called "heat island"
phenomenon, (2) lessening the load on sewage treatment plants, and (3) improving the
rhizosphere and environment for vegetation.

2. Description of Development

Attempts were made to develop permeable pavement material that contains crushed porcelain
(grain size: 0.5-3.0 mm) as aggregate, and epoxy resin adhesive for solidification. The ability of
rain-water to penetrate through the aggregate is a special feature.

(1) Crushing porcelain-insulators

Conventional methods of crushing hard porcelain-insulators produce sharp fractured fragments

that resemble broken pieces of glassware. The newly developed method uses a granulating
machine that forces crushed pieces to collide with each other thereby forming grains. Fig. 1
shows steps in the manufacture of the ceramics aggregate.

Page 27 of 30
Fig. 1 Steps in Manufacture of Ceramics Aggregate

Scrap Insulator

Crushing

Scrap Metals

Crushing

Graining

Product aggregate

Bagging

Pavement
Page 28 of 30
2) Determining optimum resin percentage

Strength and permeability of the pavement are determined by the percentage of resin that
maintains point adhesion of aggregate materials. Several samples were produced of varying resin
percentages. The samples were tested and according to the results, the resin percentage of 7.5%,
by weight, was selected as the standard specification.

(3) Experimental paving

As shown by the cross-section in Fig. 3, the surface layer of permeable pavement material made
from porcelain-insulators is bonded onto an underlying layer of permeable concrete or asphalt in
order to reduce the use of expensive epoxy resin.

Fig. 2 Structure of Permeable Pavement (Cross-section)

This permeable pavement was tested and compared with asphalt pavement to assess its
effectiveness in moderating the heat island phenomenon.

Fig. 3 Measurements of Heat Island Phenomena (Examples)

Page 29 of 30
On the morning that measurement took place, soil temperatures slightly differed depending on
types of pavement because it rained the day before. In the afternoon, however, the weather was
clear, and therefore, a greater soil temperature difference was observed between asphalt and
permeable pavements. Even during the night, no significant change in soil temperature was
observed. This observation suggested that the experimental pavement can moderate the heat
island phenomenon.

Page 30 of 30
 SETTING OF AUXILIARY SWITCH AND LIMIT SWITCH CAMS

OPERATION OF AUXILIARY SWITCH AND SETTING

CONSTRUCTION - 1

 Auxiliary switch is fixed to the rear sheet of the drive box along with bracket.
 A slotted lever is fixed with the drive shaft (square) of auxiliary switch and clamped
with bolt and nut.
 A cam is fixed with the main shaft (bottom side extended) of the gearbox below thelim
it switch cams and locked with screw and nut.
 A link plate is assembled with cam on oneside & with auxiliary lever on the other side.

OPERATION

Whenever the main shaft rotates either to close or open, the cam also will rotate and
operates the auxiliary switch through the link

Note

The auxiliary switch settings are done at works. However, in case fine tuning is required
then follow the steps given below.

Page 1 of 4
SETTING OF AUXILIARY SWITCH

 Keep the main Disconnector in open / closed condition.

 Keep the auxiliary switch lever in ‘NO’ position according to scheme.
 Rotate the cam and check the continuity of required contacts in auxiliary switch.
 If required loosen the pin in auxiliary switch slot and move the pin with in the slot
either inside or outside and lock it again.
 After this adjustment again operate and check for continuity.
 In the same way other positions also can be set.

LIMIT SWITCH OPERATION IN DRIVE MECHANISM

CONSTRUCTION-1

 Limit switch is fixed to a bracket and the entire set is fitted to the rear sheet of the
drive box.
 The operating cam is fixed to the main shaft (bottom side extended) of gear box and
locked with screw after positioning the cam.

OPERATION

Whenever the main shaft rotates either in close direction or open direction, the cams fitted
in the main shaft also will rotate and operates the relevant limit switch.

Note

The limit switch settings are done at works. However, in case fine tuning is required then
follow the steps given below.

SETTING OF LIMIT SWITCH CAM 1 AND CAM 2

 Operate the disconnector manually to open position.

 Rotate the cam and see that the cam presses the limit switch roller till it disconnects the
contact (a click sound will be heard).
 Again close the disconnector manually.
 Now operate the disconnector by motor and see that the operation is completed by the
limit switch.
 If small adjustment is required, then, loosen the screw of the limit switch CAM 1.
 Rotate the cam either towards the roller or away from the roller, as required.
 Ensure the cam makes contact with the limit switch (for opening).
 Tighten the screw of the limit switch CAM 1.
 In the same way another switch (for closing – CAM 2) can be set.
Page 2 of 4
PICTORIAL REPERSENTATION

OPEN LIMIT SWITCH CAM SETTING:

Page 3 of 4
CLOSE LIMIT SWITCH CAM SETTING:

AUXILIARY SWITCH CAM SETTING:

Page 4 of 4
 24-12-2018

Disconnector & Earth switch

O&M and Inspection Procedure

Substation Maintenance - Health & Safety Guideline

Electricity can KILL, Civil Work in Progress
 Obtain necessary work permit before start of the Job
 Be familiar with any electrical hazards in the workplace.
 Understand procedures to follow and to protect yourself when you work around electricity.
 Know when and how to report electrical problems.
 Must use the required Personal Protective Equipment's.
 Know what to do in the event of emergency involving electricity.
 Do proper Grounding of the circuit.
 Use proper tools for erection & testing activity.
 Know how to inspect electrical tools and equipment before use to make sure insulation and wiring are in good
condition.
 Use trained MHE Operator and follow SOPs for Handling heavy structures, insulators
 Working at height requires safe ladder and safety belts and helmets- please follow
 Housekeeping in site and hazards related to civil work- trench etc should be properly guarded

1
 24-12-2018

Inspection and Overhauling Schedule

After 1 Year After 5 years After 10 years
Erection& Commissioning
 Clean contact areas,  Clean contact areas,  Change all the
 Clean contact area (Male Check for any contact Check for any contact contact areas with
and Female contacts). damage and apply damage and apply new one.
Check for any damage. petroleum jelly on petroleum jelly on  Check all insulators..
 Apply petroleum jelly on contact surfaces. contact surfaces.  Lubricate all rotating
contact surfaces.  Clean all insulators..  Clean all insulators.. parts and pins.
 Clean all the insulators.  Lubricate all rotating  Lubricate all rotating  Check the auxiliary
Check for any damages. parts. parts. switch contacts.
 Check the tightness of all  Check operation of
bolted connections. After 20 years mechanical interlocks
After 25 years
 Lubricate rotating parts.
 Clean all contact
 Carry out few Open-Close  Recommended to
areas and apply
test operations manually. change all current
petroleum jelly on
 Check contact Resistance carrying blades and
contact surfaces.
 Carry out few Open-Close Operating Drive
 .Check Tightness of
test operations Electrically. mechanism boxes.
all hardware's

Disconnectors and Earth switches

Visual Inspection
 Inspect insulators for cracks, or burns or pollutants deposits.
 Inspect the all current carrying contacts and tubes.
 Check motor drive cabinet for the following:
* Heater operation
* Miniature circuit breaker (MCB)
 Check motor drive cabinet is properly latched and seals are in good condition.
 Check for visible misalignment/over travel/discoloration of primary contacts.
 Check for leakage of grease at insulator base and motor gear.
 Check earth tape connections from the Disconnectors to the substation
Earthing system.

2
 24-12-2018

Primary contact routine inspection

Where possible
 Check tightness of bolts and nuts
 Check springs of female contact for rust and its elasticity
 Check contact fingers for pitting marks, erosion, corrosion
 Check for alignment of primary contacts and arcing tips
 Check arcing tips for excessive arc damage
 Check for simultaneous closing of all blades for 3 phases
 Check linkages, rods and levers for smooth operation, ensure all joints are secured tightly.
 Lubrication of bearings with appropriate approved grease for non sealed bearings.

 The alignment of Disconnectors is very important for smooth operation. The limit switches,
the healthiness of auxiliary contacts needs to be checked periodically.
 Mis-alignment leads to Hot Spots and breakage.

Operating mechanism functional check

 Checking of Limit switches (Open/close)

 Checking of Auxiliary switches (NO+NC Contacts)
 Check operation of electrical interlocks
 Check operation of motor and it’s readings
 Lubrication of gear box and spur gear wheels
 Check operation of OLR relay and emergency stops
 Manual operational checks smooth operation
 Local and remote end operational checks

Hands on training will be given to erection team, site operators and

site in-charges about the alignment and limit switch setting of
Disconnectors and earth switches

3
 24-12-2018

Contact resistance measurement

Purpose
 Purpose of measuring contact resistance measurement is to assess the condition of the male and
female contacts against erosion or misalignment of the main contacts. Contact resistance of
Disconnectors switch contacts should be measured to check the healthiness of the current
carrying parts.
Instrument Required
 Micro ohm meter of 100 A or more current injection capacity kit with cabling accessories is
required for this test.
Evaluation
 If the value of the contact resistance exceeds the permissible limits, this could lead to over
heating of contacts, Monitoring contact resistance values is very good techniques for assessing
the condition of main contacts.

Contact resistance value should not exceed the type tested value.

Disconnectors and Earth switches

CLEANING OF CONTACT SURFACES

Silver-faced contact surfaces (bolted)

 Clean with cold cleaning agent Trichloroethylene (Without destroying silver plating
of surface of contacts).
 Apply tin layer of Grease.

Galvanized contact surfaces (bolted)

 Clean using steel wire brush
 Apply tin layer of grease immediately.

Lubricant Details
 For all pins and bushes, Shafts and bushes --- P3-Multipurpose grease or equal
 For all sliding contact parts --- Petroleum jelly or equivalent.
 For fixed parts Anti corrosive compound for electrical joints -- ACC50 or equivalent.

4
 24-12-2018

Disconnectors and Earth switches

Rust Protection:
 For Rust protection, grease G Or Tectyl- 506 is recommended.
Earth Switches:
 The earth switch is a safety device and smooth operation is to be ensured by
proper alignment.
 The earth blade contacts are to be cleaned properly for proper contact and
contact resistance to be measured to ensure healthiness.
 The earth connection from blade to earth is to be carefully checked. All the joints
should be tightened.
 Flexible copper braid connections are provided and healthiness ensured.
 All moving parts should be lubricated for smooth operation.

Disconnectors Maintenance

CLEANING PROCEDURES
Recommended cleaning methodology:
 The outdoor parts (like supporting insulators and contacts) should be checked and
cleaned at least every two years; however, this period might change according to
the environmental conditions, weather and pollution of the site.

 Every eight years a complete inspection should be performed, under the

instructions of the manufacturer personnel (checking of drives and disconnectors
operation, control of the contacts condition, etc.).

 Special care should be taken on the insulating parts and, in case of abnormal
operating conditions (such as salt accumulation, dust, cement or acid vapours), a
frequent cleaning shall be performed to avoid flashovers.

5
 24-12-2018

Surface Cleaning & Greasing

Petroleum Jelly

Steel Wire Brush

AP3- Grease

Tectyl- 506
WD40-Anto corrosion

Safety Procedure

Lockout & Tag-out Tags

6
 Factory: No. 4, EVR Street,
Sederapet, Pondicherry - 605 111.

Office: 14, CMDA Insustrial Area,

Chitnamanur Village, Maraimalai
Nagar-603209, Kanchipuram.
Document: Dis-MES-SSF-001
Site setup / Check Procedure:-
Site Setup Assembly
Assembly of 145/245/420kV Maintenance Earth Switch
Maintenance Earth Switch
Issued By: Customer Service Approved By: Quality Manager Issue: 1 (Mar’18)
Date: 17.03.18 Date: 17.03.18 V: 1 (Mar’18)

Project Information:
Order Number :

Customer Name :

Substation Name :

Site Location. :

Serial Number :

Maintenance Earth Switch:

Purpose:
The checks will show the correct assembly of the Disconnector and that its component parts are in
conformance with the design drawings.

Important Note: Before starting Disconnector ensure that the structure erection done properly and
levelling carried out with water level and sprit level. Ensure all hardware’s are tightened with torque
wrench after levelling.

Procedures:
1. Carefully remove and identify the required component parts from shipping crates and that they are in
accordance with supplied packing lists.

2. Place each Phase Base assembly on a leveled structure. Identify the base serial numbers and keep the
same in respective position as per the approved drawing.

3. Assemble Insulators onto the base assemblies. Ensure proper leveling using shims/leveling bolts (jacking
screws) Ming as required to maintain vertical alignment.

4. Assemble the Earth blade on base assembly and female fixed contacts on top of the insulator assembly
along with dummy/earth adaptor o as per the GA drawing. Do leveling/shimming for vertical / horizontal
axis as required.

5. Set and check the earth switch push pipe over toggle linkages.

6. Close the earth switch, if a particular phase is not closing properly adjust the insulators accordingly and
ensure proper closing of all three phases.

S:\QUALITY\Standard Forms\Dis-MES-Sf-001 Site setup assembly 145kV/245/420kV Maintenance Earth Switch

This document is confidential and the property of S&S Power Switchgear Equipment Limited. It can not be used, disclosed or duplicated outside the
company without prior written consent of S&S PSE.. Page 1 of 5
 Factory: No. 4, EVR Street,
Sederapet, Pondicherry - 605 111.

Office: 14, CMDA Insustrial Area,

Chitnamanur Village, Maraimalai
Nagar-603209, Kanchipuram.
Document: Dis-MES-SSF-001
Site setup / Check Procedure:-
Site Setup Assembly
Assembly of 145/245/420kV Maintenance Earth Switch
Maintenance Earth Switch
Issued By: Customer Service Approved By: Quality Manager Issue: 1 (Mar’18)
Date: 17.03.18 Date: 17.03.18 V: 1 (Mar’18)

7. Check all fixings for tightness and torque as required

8. Check all control boxes for damaged paintwork if painted

9. Fix the drive mechanism with the structure as per GA drawing.

10. Connect the Earth Down pipe to the tee bar on the base and the flanged end to the drive box flange.
Ensure flanges are mated properly and the down pipe does not pull the flange of the drive box.
(if required, use the spacers provided between the down operating pipe and drive box flange).

11. Conduct random pull test on wiring and check wire crimping for security.

12. Check all wired connections are tight.

13. Check operation of all auxiliary switches.

14. Check operation of interlocks.

15. Check switch handles for fitment.

Maintenance Earth Switch Checks:

1. Check for damaged components. Check Yes No N/A

  
2. Phase A Base level Check Yes No N/A
  
3. Phase B Base Level Check Yes No N/A
  
4. Phase C Base Level Check Yes No N/A
  
5. Phase A Insulators fitted Check Yes No N/A
  

S:\QUALITY\Standard Forms\Dis-MES-Sf-001 Site setup assembly 145kV/245/420kV Maintenance Earth Switch

This document is confidential and the property of S&S Power Switchgear Equipment Limited. It can not be used, disclosed or duplicated outside the
company without prior written consent of S&S PSE.. Page 2 of 5
 Factory: No. 4, EVR Street,
Sederapet, Pondicherry - 605 111.

Office: 14, CMDA Insustrial Area,

Chitnamanur Village, Maraimalai
Nagar-603209, Kanchipuram.
Document: Dis-MES-SSF-001
Site setup / Check Procedure:-
Site Setup Assembly
Assembly of 145/245/420kV Maintenance Earth Switch
Maintenance Earth Switch
Issued By: Customer Service Approved By: Quality Manager Issue: 1 (Mar’18)
Date: 17.03.18 Date: 17.03.18 V: 1 (Mar’18)

6. Phase B Insulators fitted Check Yes No N/A

  
7. Phase C Insulators fitted Check Yes No N/A
  
8. Phase A Earth blade fitted Check Yes No N/A
  
9. Phase B Earth blade fitted Check Yes No N/A
  
10. Phase C Earth blade fitted Check Yes No N/A
  
11. Phase A fixed contacts fitted Check Yes No N/A
  
12. Phase B fixed contacts fitted Check Yes No N/A
  
13. Phase C fixed contacts fitted Check Yes No N/A
  
14. Phase A Earth blades open/close smoothly. Check Yes No N/A
  
15. Phase B Earth blades open/close smoothly Check Yes No N/A
  
16. Phase C Earth blades open/close smoothly Check Yes No N/A
  
17. Torque bearings operates correctly Check Yes No N/A
  
18. Down Pipe fitted correctly Check Yes No N/A
  
19. Interlocks operate correctly Check Yes No N/A
  
20. Manual operation of MES satisfactory Check Yes No N/A
  
21. All fixing are tight and secure Check Yes No N/A
  

S:\QUALITY\Standard Forms\Dis-MES-Sf-001 Site setup assembly 145kV/245/420kV Maintenance Earth Switch

This document is confidential and the property of S&S Power Switchgear Equipment Limited. It can not be used, disclosed or duplicated outside the
company without prior written consent of S&S PSE.. Page 3 of 5
 Factory: No. 4, EVR Street,
Sederapet, Pondicherry - 605 111.

Office: 14, CMDA Insustrial Area,

Chitnamanur Village, Maraimalai
Nagar-603209, Kanchipuram.
Document: Dis-MES-SSF-001
Site setup / Check Procedure:-
Site Setup Assembly
Assembly of 145/245/420kV Maintenance Earth Switch
Maintenance Earth Switch
Issued By: Customer Service Approved By: Quality Manager Issue: 1 (Mar’18)
Date: 17.03.18 Date: 17.03.18 V: 1 (Mar’18)

22. All wired connections are tight and secure Check Yes No N/A
  
23. Auxiliary Switches operate satisfactorily Check Yes No N/A
  
24. Switch Handle correct and secure Check Yes No N/A
  
25. Check all operating handles are present. Check Yes No N/A
  
26. All items fitted and labeled correctly Check Yes No N/A
  
27. Petroleum jelly applied on contacts Check Yes No N/A
  

Comments

S:\QUALITY\Standard Forms\Dis-MES-Sf-001 Site setup assembly 145kV/245/420kV Maintenance Earth Switch

This document is confidential and the property of S&S Power Switchgear Equipment Limited. It can not be used, disclosed or duplicated outside the
company without prior written consent of S&S PSE.. Page 4 of 5
 Factory: No. 4, EVR Street,
Sederapet, Pondicherry - 605 111.

Office: 14, CMDA Insustrial Area,

Chitnamanur Village, Maraimalai
Nagar-603209, Kanchipuram.
Document: Dis-MES-SSF-001
Site setup / Check Procedure:-
Site Setup Assembly
Assembly of 145/245/420kV Maintenance Earth Switch
Maintenance Earth Switch
Issued By: Customer Service Approved By: Quality Manager Issue: 1 (Mar’18)
Date: 17.03.18 Date: 17.03.18 V: 1 (Mar’18)

Statement of Acceptance

Upon satisfactory completion of all the checks outlined in this Acceptance Check Document, it is state stated
that as at today’s date being the site Acceptance date, the Equipment’s identified have been properly
documented and witnessed. Any discrepancies, resulting from the Checks specified in this document are
accepted subject to any observations /comments raised during the Site Acceptance.

1. The Equipment have been duly accepted at the Site in accordance with and subject to the provisions of
the purchase contract and the minutes raised during any progress meetings.
2. Duly appointed and authorised technical experts have inspected the Equipment to ensure that they
conform to technical specifications of the purchase contract.
3. The equipment’s are fully equipped in accordance with the technical specifications of the purchase
contract and are satisfactory in all respects.
It is understood that all outstanding NCR’s / Comments and Corrective Actions will be rectified prior to final
commissioning and or notification given of any items that need to be rectified

CERTIFIED BY:

S&S PSE Service Engineer Date

Contractor Representative Date

Customer Representative Date

S:\QUALITY\Standard Forms\Dis-MES-Sf-001 Site setup assembly 145kV/245/420kV Maintenance Earth Switch

This document is confidential and the property of S&S Power Switchgear Equipment Limited. It can not be used, disclosed or duplicated outside the
company without prior written consent of S&S PSE.. Page 5 of 5
 S&S POWER SWITCHGEAR EQUIPMENT LTD.,

Works: Corporate Office:

No.4, EVR Street, Plot No:14, CMDA Industrial Area-II,
Sederapet, Chithamanur Village, Maraimalai Nagar-603209,
Puducherry – 605 111, India. Kancheepuram Dist, Tamilnadu, India.

www.sspower.com

420kV FEE(MES) DT.: 23.12.18