Building Substation Business Skills

4Construction Aspects of Substation

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 Safety First

PLAN
AHEAD TO GET THE JOB DONE
SAFELY

PROVIDE
THE RIGHT EQUIPMENT & PPE

TRAIN
EVERYONE TO USE THE
EQUIPMENT SAFELY
KEC INTERNATIONAL LIMITED
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Proportion of Civil, Electrical Erection, Testing &
Commissioning

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 Steps of Execution

1.Planning

a. Start up Activities- Checklist

b. Mobilisation of site
c. ERT & Soil Investigation
d. Monitoring as per L2
e. Supply & Engineering issues Tracking

2. Execution

a. Civil
b. Electrical Erection
c. Testing & commissioning

3.EHS-Safety & Quality

4. Project Closure Checklist

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Construction Synopsis of Substation Projects

• Pre-requisites to Construction activities ( Civil & Electrical )

1

• Startup Activities
2

• Drawing & Documents List

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Construction Synopsis of Substation Projects
• Civil Construction
• Preliminary
• Transformer and Outdoor Equipment
4 • Building Works
• External Works

• Electrical Installation
• Preliminary works
• Transformer and Outdoor Equipment
5 • Indoor Equipment
• Other Electrical Installation

• Fire Fighting System

• DG Set
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Construction Synopsis of Substation Projects

• Testing and Commissioning

• Electrical Equipment Testing : Outdoor & Indoor
• Mechanical Equipment Testing
7 • Overall Scheme Testing

• Safe Practices in Substation

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 KEC International Limited
1. Pre-requisites to Construction Activity
1. Pre- requisites to Construction Activities

• Site handing over from client

• Municipal/ Government Clearances
• Site survey
• Soil Investigation Report and its
impact
• Earth Resistivity Report ( ERT) and its
impact
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 KEC International Limited
2. Site Startup Activities
 2. Site Start Up/Development Activity

• Construction of Site Office – Porta Cabin

• Arrangement of Construction Power from SEB.
• Digging of Bore well for Water Supply
• Fixing of Reference Level (RL) , Formation Ground
Level (FGL) and Benchmark at site.
• After Fixing the levels , as per Contour plan levelling,
Cutting & filling of sand is decided to achieve the
Ground level.
• T&P Required – RMC Plant, Poclain, Rock Excavator,
JCB, Dumper , Tractor, Leveller ,
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 3. Drawing & Documents List
• Tower & Equipment Foundation Plan Layout, Road Layout, Drain
Layout
• CRB- Architectural- GF,FF Plan, Section, Elevation

Civil • Transformer Foundation Drawing – Plan & section

• Cube Testing, Trial Mix , Compaction Test & Slump Test
• Sample Approvals of Sand , Aggregate, Concrete Design Mix ,
Cube test from Client.
• SFQP of client

• Single Line Diagram

Electrical • Plan & Section Layout , Tower erection Drawings & BOM
• Stringing Arrangement, Busbar Layout
• SFQP Approval from Client

• Fire Fighting Hydrant system

Mechanical • Isometric Plan
• Piping Layout

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 KEC International Limited
4. Civil Construction Activity
 Outdoor Switchyard – Tower Foundation

Column Shuttering with Bolt fixing Column Casting

Outdoor Switchyard – Equipment Foundation
Transformer Foundation

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Transformer Foundation

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ACP ROOMS

1.Cable Trench
2.Tiling – Floor & side wall
3.Clay Roof Tiles
4.Channel Fixing for panel arrangement
5.Industrial AC
6.Fire Door
7.Cable Vent
8.Illumination

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ACP ROOMS - Photo

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Fire Fighting Pump House & Water Tank Building

1.Pump Foundations
2.Shutter
3.Piping Foundation
4.Cable Trench
5.Panel foundation
6.Air vessel Foundation
7.Channel Fixing

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FFPH & Water Tank - Photos

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Control Room Building

1. Size of the building

2. FF , SF Slab Casting
3. ACDB, DCDB Room
1. Cable trenches
2. Channel , Angle Fixing
4. Battery Room
5. Pantry
6. Conference room
7. Control room
8. Office area
9. Aluminium Doors & Windows, Shutter
10.False Ceiling
11.Split & Cassette AC
12.Conduiting & Illumination
13.Tiles , Granite Fixing
14.Anti weed Treatment 22
15.Water Proofing
Control Room Building -- Photos

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Roads

1.Excavation
2.WBM – 3 layers
3.Water proofing sheet
4.PCC
5.RCC
6.Curb Stone

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Roads - Photos

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Substation Internal Road
Yard PCC

1.Backfilling of sand
2.Levelling
3.Compaction
4.PCC

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Yard PCC- Photos

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45 mm Size Metal Spreading over Yard PCC

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GIS Building Civil Work
1. Foundation
Excavation
Boulder Packing
PCC
Reinforcement with Insert Plate welding
RCC
2. Cable Trench
Excavation
PCC
Raft
Wall RCC
Angle welding 29
GIS Building Civil Work
3. Brick Work & Plastering
4. PEB Erection
Column Erection
Top Beam Erection
Roof Sheeting
Side Puff Panel erection
5. Shutter Fixing & Aluminum Doors & Windows
6. Ventilation System Ducting and Panel erection
7. EOT Crane Erection
8. Illumination

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GIS Building Civil Work

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 KEC International Limited
5. Electrical Erection Activity
Equipment Erection– Outdoor ( Photos)

Execution Sequence for Switchyard (without Transformer):

1) Civil Gantry Tower Foundation work à Structural
Erection à Stringing
2) Civil Equipment Foundation Work à Structural
Erection à Equipment Erection
3) Main Grid Earth Mat Laying à Earthing connection
to structure & Equipment
4) Cable Trench, Road and Drain construction à Cable
Tray support fixing
5) Equipment connection and Rigid Bus installation
6) AC Kiosk installation
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Equipment Erection– Outdoor ( Photos)

7) LT Switchgears installation
8) Cable Laying and Termination
9) Individual Equipment Testing
10) Control Panels Installation in AC Kiosk
11) Testing of control and protection system
12) Obtaining Electrical Inspection Clearance
13) Commissioning

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5. Electrical Erection – Outdoor Switch yard -
Earthing
1.Main Mat Earthing
Excavation 1.5 mtr. deep
1. Laying of 40mm MS Rod along x-axis & y-axis
2. Lap joint of 240mm between two rods
3. Bituminous paint on joints
4. Spacing of 15m * 15m
5. Backfilling
2.Auxiliary Mat
6. Size – 1.5m * 1.5 m
7. To be Laid at Mom Box of Isolators only
3.Risers
8. 3 mtr. long 40 mm MS Rod to be connected between main mat and
Equipment Structure.
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Earthing - Photos

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 Tower and Equipment Erection – T&P List
1 10 Ton capacity Hydro Crane 2 Nos
2 Chain Block 10 Ton capacity 10 Nos
3 Chain Block 5 Ton Capacity 25 Nos
4 Chain Block 3 Ton Capacity 25 Nos
5 Chain Block 2 Ton Capacity 25 Nos
6 Chain Block 1 Ton Capacity 30 Nos
7 Chain Block 0.5 Capacity 15 Nos
8 Chain Chuck 1.5 Ton capacity 15 Nos
9 Rope Chuck with rope 3 Ton capacity 10 Nos
10 Derrick 4 Nos
11 Rope chuck with rope 1 Ton capacity 10 Nos37
 Tower & Equipment Erection – T& P List
17 Manila Rope Pulley ( Single way ) 10 Nos
18 Manila Rope Pulley ( Double way ) 12 Nos
19 Manila rope Pulley ( Three way ) 6 Nos
20 Wire rope Pulley ( Single way ) 6 Nos
21 D Shackle 20 Ton & 50 Ton capacity 20 Nos
22 D Shackle 10 Ton capacity 30 Nos
23 D Shackle 5 Ton capacity 40 Nos
24 D Shackle 3 Ton Capacity 50 Nos
25 D Shackle 2 Ton capacity 50 Nos
26 D Shackle 1 Ton capacity 50 Nos
27 Eyebolt ( Various Sizes ) 100 Nos
28 Eyenut ( Various Sizes ) 5 set
29 Crowbar 20 Nos
30 Nylon Slings different capacity 1 Lot
31 Power Winch 10 Ton 1 No
32 Power Winch 5 Ton 2 Nos 38
Tower & equipment Erection - Photos

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Tower & equipment Erection - Photos

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Stringing of Conductor / Earthwire - Photos

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 Equipment Erection-- Outdoor
1. LA Erection
1. Erection of Lower Post, Middle Post, Top Post
2. Erection of Corona Ring
3. Erection of Surge Counter
2. BPI Erection
1. Erection of Lower Post, Middle Post, Top Post

3.CVT Erection
4.Wave Trap Erection
5.Isolator Erection
6.Circuit Breaker Erection
2. Erection of Pole
3. Erection of Interrupter assembly with Manlifter
4. Erection of corona rings
5. Erection of Mechanism Box
6. Vacuum in Interrupter assembly with Vacuum Machine
7. SF6 gas Filling
8. Erection of Ladder
7.Current Transformer Erection 42
Equipment Erection– SF6 Circuit Breaker

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 Transformer Erection
• What Is Transformer?

• A Transformer is a static machine used for transforming Power form one level
to another level without changing frequency.
• Two Types of Transformer - - Step up & Step Down Transformer
• Power Transformers do not directly connect to the consumers , So Load
fluctuations are very less.
Erection Parts of Transformer
• Transformer body on Foundation

• Radiator Erection
• Bushing Erection
• Pressure Relief Valve ( PRV)
• Lighting Arrestor Erection
• Cooling Fans Erection
• Conservator Tank Erection
• Cable Boxes with WTI , OTI
• Vacuum filling
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• Buchholz Relay
Transformer Erection-- Photos

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Transformer Erection-- Photos

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STAGES OF ERECTION

 TRANSFORMER UNLOADING
 TRANSFORMER MAIN TANK DRAGGING
 TURRET AND BUSHING ERECTION
 RADIATOR ASSEMBLY AND PIPELINE ALONG WITH CONSERVATOR
TANK
 ERECTION AND ISTALLATION OF OLTC ALONG WITH RTC PANEL
 FIXING OF A-FRAMES ALONG WITH FAN ASSEMBLY
 VACUMMING OF MAIN TANK AND OIL FILTERATION
 INSTALLATION OF HYDROGEN MONITER ALONG WITH PPM COUNTER
 OIL SAMPLE TESTS ALONG WITH DGA
 COMMISSIONING CHECKS ALONG WITH FRA
PRE COMMISSIONING TESTS
 OIL TESTS WHICH INCLUDES BDV, PPM, ACIDITY, DGA,
HYDROGEN LEVEL etc.
 ELECTRICAL CHECKS
TAN-DELTA OF PRIMARY AND SECONDARY BUSHING
IR TEST
MAGNETISING CURRENT TEST
NEUTRAL CT TESTS (IR, RATIO, PRIMARY INJECTION etc.)
Neutral displacement/ balancing test.
REF CKT TEST WITH STAR POINT IDENTIFICATION
FRA ANALYSIS
CORE BALANCING TESTS
TRAFO BUSHINGS
TRAFO MAIN TANK
RADIATOR AND A-FRAME ASSEMBLY
TOTAL TRAFO ASSEMBLY
TOTAL TRAFO ASSEMBLY WITH RAIL
CUM ROAD
Transformer Erection-- Photos

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Transformer Erection-- Photos

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Erection of Jumper, Dropper-- Outdoor

1. Measurement of Conductor for Dropper & Jumper from Main Bus to

Equipments for Cut Length.
2. Erection of Cut length of conductor through Bolted type Clamping.

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Erection of Jumper, Dropper-- Outdoor

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Interconnection of Equipments

1. Interconnection of Equipments is done through 4” Al. tube .

2. This tube is of standard size 9 mtr. in length.
3. For jointing of pipes special type of welding is required
1. Argon Welding
2. DP Test
3. Radiography Test

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Interconnection of Equipments

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 Indoor Equipments Erection
1. Control room Building
1. AC Distribution Board
2. DC Distribution Board
3. Battery / Battery Charger
4. Switchgear panels
5. Substation Automation System
6. SCADA- System Control & Data Acquisition – It is a system operating with
coded signals over communication channels so as to provide control of
remote equipment
2. ACP Rooms
1. PLCC Panels and cabling
2. Industrial AC & Cabling
3. Illumination & cabling
3. Fire Fighting Pump House
3. Pump Erection
4. Air Vessel Erection
5. Piping
6. Panels Erection & Cabling
7. DG Erection 60
8. Piping upto Transformer/ Reactor
Indoor Equipments - Photos

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Battery Room
Indoor Equipments - Photos

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Switch gear panels
Indoor Equipments - Photos

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Control panels
Indoor Equipments - Photos

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Control & Relay panels
Cabling of Power & Control Cables
1. All the cables are laid through Cable trenches in substation as per approved
Cable Schedule .
2. All the Power Cables are laid through Bay Marshalling Kiosk installed in
substation upto ACDB Panels in control room.
3. All the control cables are used for interloping between Equipments for their
operation from Control room.
4. After laying of cables , for termination we use Lugs & Glands at both ends of
cable & equipment, Panels etc.

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Cabling of Power & control Cables- Photos

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GIS Erection Activities

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GIS Erection Activities

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 KEC International Limited
7. Testing & Commissioning Activity
7. Testing and Commissioning - Outdoor Equipment

• Transformer : Ratio, Insulation Resistance, Winding Resistance, Oil BDV &

Outdoor PPM , Tan- Delta, HV-LV, Magnetizing Current & Balance

• Circuit Breaker: Insulation Resistance, Timing Cycle, Local Operations, Gas
Pressure Check, Alarm

Equipmen • CT/CVT/LA: Insulation Resistance, Ratio, Polarity

• Disconnector (Isolator) : Insulation Resistance, Local Operations and
Interlocks, Contact Resistance & Motor Test

t testing • Capacitor Banks: Insulation Resistance , Capacitance & Reactance

• Requirement of Specialist

Tools & •
•
Insulation Resistance & Earth Resistivity Tester
Primary/ Secondary Injection

Test •
•
•
Tan – Delta & Hi-Pot Kit
Breaker Timing Kit, DILO Kit for Gas Filling & Leak Detector
Vacuum Machine, Oil Filtration Machine , BDV Kit
Equipmen •
•
Multi-meter, Continuity Tester
Polarity Test Kit , Megger 5kv

t
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7. Testing and Commissioning - Outdoor Equipment

1. Transformer Testing

1. Ratio Test –
First, the tap changer of transformer is kept in the lowest position and LV terminals
are kept open.
Then apply 3-phase 415 V supply on HV terminals. Measure the voltages applied
on each phase (Phase-phase) on HV and induced voltages at LV terminals
simultaneously.
After measuring the voltages at HV and LV terminals, the tap changer of
transformer should be raised by one position and repeat test.
Repeat the same for each of the tap position separately.

2. Winding Resistance– It is Carried out to calculate the I2R Losses,

Calculation of Winding Resistance at the end of temperature rise test.
For Star Rating Winding resistance shall be measured between Line &
Neutral , For delta connected Windings measurement is done between line
terminals. The resistance can be measured by using kelvin Bridge Method or
Ohm meter of 25 A. 71
 7. Testing and Commissioning - Outdoor Equipment
3. Oil Breakdown Voltage Test
The insulation oil of voltage- and current-transformers fulfills the purpose of
insulating as well as cooling. Thus, the dielectric quality of transformer oil is a
matter of secure operation of a transformer.

Procedure:-
The transformer oil is filled in the vessel of the testing device. Two standard-
compliant test electrodes with a typical clearance of 2.5 mm are surrounded by
the dielectric oil.
A test voltage is applied to the electrodes and is continuously increased up to the
breakdown voltage with a constant, standard-compliant slew rate of e.g. 2 kV/s.
At a certain voltage level breakdown occurs in an electric arc leading to a collapse
of the test voltage.
An instant after ignition of the arc, the test voltage is switched off automatically by
the testing device. Ultra fast switch off is highly desirable, as the carbonisation due
to the electric arc must be limited to keep the additional pollution as low as
possible.
Conclusion: The lower the resulting breakdown voltage, the poorer the quality of 72
the transformer oil!
 7. Testing and Commissioning - Outdoor Equipment
4.Tan Delta Test –
A pure insulator when it is connected b/w Earth & line , it behaves as a capacitor.
The cable, winding, current transformer, potential transformer, transformer bushing,
on which tan delta test or dissipation factor test to be conducted, is first isolated from
the system. A very low frequency test voltage is applied across the equipment whose
insulation to be tested. First the normal voltage is applied. If the value of tan delta
appears good enough, the applied voltage is raised to 1.5 to 2 times of normal voltage,
of the equipment. The tan delta controller unit takes measurement of tan delta values.
A loss angle analyser is connected with tan delta measuring unit to compare the
tan delta values at normal voltage and higher voltages, and analyse the results

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 7. Testing and Commissioning - Outdoor Equipment
Circuit Breaker Test
1. IR Test:-
IR test on each pole, phase to phase & phase to ground with the CB Closed & across
each pole for one minute. Performs on all the control wiring also.
2.Timing Cycle
3.Local Operation & Gas Pressure Check , Alarm

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7. Testing and Commissioning – Indoor Equipment

Indoor • GIS & Switchgear: Ratio test, Interlocks, Insulation resistance, Gas
Pressure, HV test
• Battery & Battery charger: Insulation resistance, Charging- Discharging

Equipmen Cycle, Scheme Checks

• LV Panels : , Insulation Resistance, Scheme Checks
• CRP & SAS: Relay Test, Scheme & Wiring Checks, IO List checks

t testing • Requirement of Specialist

Tools & •
•
Insulation Resistance & Earth Resistivity Tester
Phase Sequence Meter

Test •
•
•
Primary/ Secondary Injection
Hi-Pot Kit
Breaker Timing Kit, DILO Kit for Gas Filling

Equipmen •
•
•
Vacuum Machine,
Multi-meter, Continuity Tester
Relay Test Kits

t • Licensed Software Requirement from Vendor

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7. Testing and Commissioning – Mechanical Equipment

Fire
Fighting • HVAC
• Firefighting : Pressure Test
System • DG Set

Testing

• Remote Operations of Individual Equipment

Overall with Interlocks
• Status of Each Equipment at Control Room
Scheme • Special Protection Testing: Distance /Differential
• Interface with LDC
Checks • Cable Tests: HI-POT Test

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Site Safety Practices & Quality Assurance

Safety Prize distribution at site Regular Safety Pep talk at site

Quality Checks and

Material from reputed
manufacturers ensured
Best Quality during
execution at site.

ZERO ACCDIENT TILL DATE

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KEC International Limited
Thank You