Knapp Mill WTW Treated Water Pump House HV Supply O & M Manual

Operations & Maintenance Manual
Electrical Services
At
Treated Water Pump House

Knapp Mill
Bournemouth & West Hampshire Water
Final Revision
Date: 15/06/09
SEC BOURNEMOUTH
Treated Water Pump House-Knapp Mill
Electrical
Operations and Maintenance Manual
For

Knapp Mill
Issue 1 Revision A Date 10/06/09
Prepared by SEC Bournemouth

Unit 3, Old Generator House
Bourne Valley Road
Branksome
Poole
Dorset BH12 1DZ
Checked by S. Ramsier For SEC

Approved by For Client
Project Ref: 163021 Operations & Maintenance Manual Section 1 Page 1

Contents
1. Introduction and O & M Manual Issue/Revision Chart
2. System Description
3. Specialist Systems Technical Data
4. Operating Procedures
5. Maintenance Procedures
6. Emergency Procedures
7. Plant Malfunction
8. Recommended Spares
9. Design Data
Test and Commissioning Certificates
10. Manufacturers & Suppliers Details

Equipment Details
11. CDM Health and Safety Information
12. Schedule of Drawings

Copies of Drawings

O & M Manual Issue/Revision Chart
Issue/Revision Details Of Alterations Sect Rev Copies

Date

Section 1 Introduction
Contents
1.1 Southern Electric Contracting Ltd.
1.2 Office Details
1.3 Abbreviations Used in this Manual
1.4 Using This Manual
1.5 Health and Safety at Work
1.1 Southern Electric Contracting Ltd.
Southern Electric Contracting Ltd (SEC) is a multi-faceted company at the leading

edge of technology and innovation.
The company employs over 3,500 staff comprising design engineers, estimators,
project managers, mechanical and electrical operatives, and support staff. Such
highly professional expertise enables the company to supply its service excellence
to any part of the United Kingdom.
The company's main business activities encompass commercial and industrial M&E
contracting, public lighting, security and hazardous area control, instrumentation,
together with data communication systems and domestic home services.
SEC is committed to service excellence and this commitment is your safeguard.
Southern Electric Contracting Ltd is part of the SSE Contracting Group.

1.2 Office Details
Head Office and Registered Office
55 Vastern Road
Reading
Berkshire
RG1 8BU
Tel: 0118 953 4243
District Office Responsible for Project

Bournemouth Office
Unit 3, Old Generator House,
Bourne Valley Road,
Branksome,
Poole,
Dorset BH12 1DZ
Contact Name: Steve Ramsier

E-mail: steve.ramsier@sec.eu.com
Tel: 01202 784980
1.3 Abbreviations used in this manual
CPC Circuit Protective Conductor
DB Distribution Board
MCB Miniature Circuit Breaker
MCCB Moulded Case Circuit Breaker
PSU Power Supply Unit
UPS Uninterruptible Power Supply
PPE Personal Protective Equipment
COSHH Control of Substances Hazardous to Health
I.E.E Institute of Electrical Engineers
HRC High Rupturing Capacity
etc

1.4 Using This Manual
This Operations and Maintenance (O&M) Manual forms part of the Health & Safety
File and is specific to the project described in 2.2 Scope of Works.
The manual should be made available to the following personnel for reference
purposes:
Maintenance Staff
Any persons employed to work on the installation and systems
Designers
Any revisions created for this manual should be recorded on page 3 of this section.
1.5 Health & Safety At Work
General
1. It is the duty of every employer:
a. to ensure as so far as is reasonably practical the health, safety and

welfare at work not only of all his employees but of all persons who use
his premises or are affected by his undertaking.
b. to provide information necessary for (a) above.
2. The equipment and materials referred to in these instructions are safe and
without risk to health when used and maintained in accordance with the
schedules and manufacturer's literature contained herein.
3. It is the duty of every employee while at work:
a. to take reasonable care for the health and safety of himself and of
others who may be affected by his acts or omissions at work.
4. In undertaking maintenance works, it should be noted that compliance with at

least the following is a minimum requirement:
Health and Safety at Work Act 1974 and Supplementary Regulations

Electricity at Work Regulations 1989
The requirements of the COSHH Regulations 2002
British Standards, Codes of Practice and Current State Legislation

FAILURE TO COMPLY WITH RELEVANT HEALTH AND SAFETY AT

WORK REGULATIONS WILL MAKE EMPLOYERS AND EMPLOYEES
LIABLE TO PROSECUTION.
5. Where appropriate to the work, protective equipment (goggles, screens,

respirators, protective clothing, safety belts etc) must be used.
6. Work must never be carried out under conditions where there is an element of
danger if it is reasonably practical to eliminate the risk.
7. Never lift or carry loads which are liable to cause injury. Suitable lifting
equipment or other tackle must be used.
8. Before working on electrical equipment which could present a disruption of

electrical supply to final circuits, the work should only start once a "Permit to
Work" control system is in place that ensures all necessary safety precautions
are identified, understood and put into effect.
9. Care must be taken and adequate protection provided to prevent fire when
welding or carrying out similar operations involving the application of heat.
Arc welding demands protective screen. Precautions against explosions are
laid down for working on tanks or containers which have held explosive or
flammable substances.
10. Fire Alarm systems must be regularly checked and kept in working order.
11. The means of escape from the building (as specified in the certificate issued
by the Fire Authority) must be maintained and at all times, kept free of
obstruction.
12. Anyone in control of industrial or commercial premises must prevent or render

inoffensive any potentially harmful emissions into the atmosphere.
13. Hand and other small power tools should be suitable for operation from a 110
volt electrical supply.
14. Safe working conditions must be provided to give adequate protection and
also safe access and egress where necessary. Access doors and panels to
all areas containing Mechanical and Electrical plant (e.g. plant or switch
rooms, electrical panels, fan chambers, etc) must carry appropriate warning
notices. Proper scaffolds, guard rails, toe boards, etc and ladders must be
provided and used. Refer to regulations.
15. Never work on moving parts of machinery, care should be taken when
working on the stationery parts of the machinery, which involves making
certain that the moving parts are adequately protected by suitable guards
before work commences.

16. Adequate ventilation must be provided. Special precautions must be taken in
atmosphere where there is a stream, smoke, asbestos or other unhealthy or
dangerous contaminates, or in confined spaces.
17. First Aid boxes or cupboards of the prescribed standard and containing only
First Aid requisites, must be provided in accessible positions and kept clean
and in good repair. The minimum quantity and quality of dressings, etc, is
relevant to the number of persons employed. Where this is required by the
regulations, a responsible and readily available person trained in First Aid

treatment must be named and placed in charge of the equipment during
working hours.
18. Provisions for environmental protection will satisfy the relevant aspects of
ISO 14001.

Section 2 System Description
Contents
2.1 General Project Overview
2.2 Scope of Works
2.3 Building Description
2.4 Health & Safety
2.5 Detailed Engineering
2.1 General Project Overview
The design and installation of a new HV supply to the new treated water pump
house. We will be breaking into the existing HV ring and installing two new 1000kVA
transformers including connection to a new LV switch panel installed by others.
2.2 Scope of Works
The contract covered by this manual included the following works:
The supply and installation of new transformers.
The supplying and installation of a associated HV cabling.
Testing and commissioning

2.3 Building Description.
The new sub-station building is of traditional construction being of brick elevations,

concrete base and tiled roof housing the HV equipment and LV distribution gear.
2.4 Health & Safety.
Refer to the works Health & Safety Plan and associated risk assessments. Method
statements were issued for particular sections of work: Section 11 of this Operations
& Maintenance Manual refers.
2.5 Detailed Engineering.
Detailed engineering of the electrical works was carried out to ensure that the
installation met the clients requirements and complied with the requirements of the
current edition of the IEE Wiring Regulations (BS 7671), the Electricity at Work
Regulations and current industry best practises.

Section 3 Specialist Systems Technical Data
Contents
3.1 High Voltage transformers
3.2 High Voltage Switchgear

INSTALLATION, COMMISSIONING,
OPERATION & MAINTENANCE
INSTRUCTIONS FOR
DISTRIBUTION TRANSFORMERS
OIL FILLED NATURALLY COOLED
www.wilsonpowersolutions.com
CHECKED & APPROVED
NAME SIGNATURE DATE
J.R.BENNETT 21.04.2005
2
AMENDMENTS
REVISED DESCRIPTION APPROVED DATE
3
INDEX PAGE
1.0 INTRODUCTION 6
1.1 General
1.2 Caution Notes
1.3 Health & Safety
2.0 DISTRIBUTION TRANSFORMER 8
2.1 General
2.2 Standard Fittings
2.3 Optional Fittings
3.0 GENERAL INFORMATION 10
3.1 Arrangements for Transport

3.2 Recommended Inspection
3.3 Unloading & Handling of Transformer at site
3.4 Storage
4.0 INSTALLATION 13
4.1 Precautions
4.2 Location and Site Preparation
4.3 Insulating Oil
4.4 Gaskets and Joints
4.5 Terminals / Bushings
4.6 Cable Boxes
4.7 Conservator
4.8 Dehydrating Breather
4.9 Explosion Vent / Pressure Relief Device
4.10 Buchholz Relay
4.11 Temperature Indicators
4.12 Cooling Radiator
4.13 Current Transformers
4.14 Earthing Connection
4.15 Paintwork
4.16 Completion of Installation Work
5.0 COMMISSIONING 25
5.1 Purpose
5.2 Commissioning Tests:
5.2.1 Insulation Resistance (IR) Test
5.2.2 Break-Down Voltage (BDV) Test
5.2.3 Voltage Ratio Test
5.2.4 Winding Resistance Measurement Test
5.2.5 Marshalling Box Scheme Check
5.2.6 Buchholz Relay Test
4
INDEX PAGE
5.2.7 Temperature Indicator Test

5.2.8 Off-Circuit Tap Selector
5.3 Sensible Additional Checks
6.0 MAINTENANCE 28
6.1 General
6.2 Insulating Oil
6.3 Internal - Transformer Core & Windings
6.4 External Outdoor / Indoor Terminal Bushings
6.5 Cable Boxes
6.6 Cooling Radiators
6.7 Conservator
6.8 Oil Gauges
6.9 Dehydrating Breather
6.10 Buchholz Relay
6.11 Explosion Vent or Pressure Relief Device
6.12 Temperature Indicators
6.13 Sealing Gaskets
6.14 Bolt, Nuts & Fasteners
6.15 Paintwork
6.16 Valves
6.17 Maintenance Schedule
5
1.0 INTRODUCTION
1.1 GENERAL
1.1.1 A Transformer supplied by Power & Distribution Transformers Ltd.,

Leeds, U.K., is designed, manufactured and tested with the latest developed
technology and with strict quality control so as to ensure a long and trouble
free service. With proper installation, commissioning, protection and timely
maintenance during operation, the users should receive from it the service
which they may reasonably expect.
1.1.2 The purpose of this Instruction Manual is to provide guidance on the

installation, commissioning and maintenance of oil-filled transformers. This
guide is necessarily general in nature. In the event of any doubt, query arises
or need for any further information or any irregularity / deviation from IEC / BS
/ Equivalent Standard, observed, please refer the Supplier for clarification and
possible assistance.
1.1.3 The transformer along with all its accessories / fittings should be
installed, commissioned, operated and maintained under the supervision of a
competent electrical engineer in accordance with relevant statuary
requirements and good engineering practice, including Code of Practice,
where applicable, and properly used within the terms of specification.
1.1.4 For the UK and International Standards & Codes of Practice, reference
should also be made to the current edition / publication of BSI: Standards
Catalogue, ESI: 35-1, IEC: Catalogue of Publication, etc.
1.1.5 A list of Standards & Codes of Practice for selection, construction,

application and operation of various transformers will be furnished on request
to suppliers.
1.2 CAUTION NOTES
1.2.1 No transformer should have rated service voltage applied to it until ALL
preliminary work and pre- commissioning tests and checks have been
satisfactorily completed.
1.2.2 No high voltage tests should be applied to any transformer without

making reference to the original supplier Power & Distribution Transformers
Ltd., Leeds, UK.
1.2.3 A transformer which has been commissioned and then removed from
service for a length of time should be rechecked as when first commissioned
PRIOR to re-energising and placing the transformer back into service.
1.3 HEALTH AND SAFETY
1.3.1 Materials or components that are liable to be exposed or handled in

normal operation & maintenance and which present any hazard to health are
covered here.
6
1.3.2 Electricity at Work Regulations - 1989 applies to the UK Electrical
Installation as per Memorandum of Guidance on the Electricity at Work
Regulation from HMSO.
1.3.3 Also refer Regulations for Electrical Installation BS:7671 for

installation up to 1000V AC and Safety in Electrical Testing HS(G)13 from
HMSO, ISBN 011 883 283 0.
1.3.4 Important: Flash Test on Winding is not recommended and if for any
reason, further testing is required at site, then it must be performed at reduced
voltages only, which is value calculated by subtracting the service voltage
from the original test voltage as tested as per the manufacturers test
certificate, halving the obtained value and then adding the service voltage as
explained in the example below;
Test Voltage as per Test Report 28kV

Service Voltage 11kV
Half of Difference Voltage 17 / 2 = 8.5kV
Recommended Test Voltage at site 8.5 + 11 = 19.5kV
1.3.5 During design of an electrical distribution system including a

transformer, care shall be taken with the following aspects;
a) selection of transformer installation site having adequate ventilation,

normal operating temperature, protection against fire, moisture,
explosion, etc.
b) selection of electrical protection at both primary & secondary side
against over-load, short-circuit, earth-fault, etc.
c) provision for regular inspection, maintenance
1.3.6 In addition to the instruction given in this manual, BS / IEC / equivalent

standards and local regulation should also be referred for other details
regarding the design, materials and performance
1.3.7 Excessive and prolonged skin contact with transformer oil (mineral oil)
should be avoided. For further information regarding oil handling, please refer
Effect of Mineral Oil on the Skin [SHW295] & Cancer of the skin caused by
oil [MS(B)5].
1.3.8 A list of standards applicable to distribution transformer is given as

below;
a) Power Transformer IEC:76

b) Bushings for alternating voltage above 1000V IEC:137
c) Loading guide for oil immersed transformer IEC:354
1.3.9 ADDITIONAL INFORMATION / SUGGESTION WILL BE GIVEN ON

REQUEST TO ORIGINAL SUPPLIER.
7
2.0 DISTRIBUTION TRANSFORMER
2.1 GENERAL
2.1.1 All products have been designed, tested and supplied as per the
specification and standards quoted, order acknowledged and subsequent
modification as approved.
2.1.2 Some accessories / fittings / components referred in this manual are

supplied only when specified and will not be incorporated into all the
transformers supplied.
2.1.3 As efforts are being constantly made to improve designs and service,
the equipment supplied may differ in minor details from the data given herein.
2.1.4 For information about the equipment actually supplied, ALWAYS refer
to the Drawings, Technical Specification Sheet, Manufacturers Instruction /
Product Catalogue of the Accessories / Fittings and such documents
furnished with the hand-over documents.
2.1.5 As the title implies the equipment distributes the power to various
circuits at low voltage, generally 433V. For an anticipated variation appearing
in the primary side supply voltage, the secondary side supply voltage is
maintained within prescribed limits by the use of an Off-Circuit Tap Selector
(OCS) mounted integrally within the transformer tank. OCS is connected into
the Primary Side / HV Side Voltage Variation Tappings. The OCS should be
operated ONLY when the transformer is Off-Circuit i.e. totally isolated from
the power supply, otherwise there can be heavy arcing at tap connections
which can pose a fire / explosion hazard.
2.1.6 Transformer tank is suitably designed to allow the safe lifting &
transportation of the complete unit without over-straining the joints / clamps
that are supporting the core & winding assembly, radiators, etc. and without
any oil leakage.
2.1.7 All floor mounted transformers are provided with skid type under-base
with pulling eyes or axle holes suitable for handling with roller bars. If
required, foundation / mounting holes are provided in the under-base.
2.1.8 All pole mounted transformers are provided with either hanger bracket
suitable for pole mounting or flat base with mounting holes suitable for
platform mounting.
2.1.9 The tank, core, windings, associated structures and leads of

transformers are constructed to withstand both the thermal and mechanical
effects arising from a short-circuit at the output terminals of the unit. Normal
construction consists of a three limb magnetic core assembly, with each
phase comprising of separate HV and LV Coils properly insulated, suitably
supported and clamped. The whole assembly / structure is totally immersed in
an oil-filled, fabricated tank.
2.1.10 Input connection to the transformer is via customer supply. This could
8
be either overhead line, terminating at outdoor bushings or HT Cables
terminating at HV Cable Box. Output connection from the transformer is via
customer supplied LT Cables connected at LV Cable Box, feeding the load of
the connected power system.
2.1.11 A Marshalling Box, if required, is provided to marshal all the

transformer auxiliary wiring for convenience of external connection.
2.1.12 In addition to the standard Fittings / Accessories, the other optional /

additional items as required by customers specification are provided. All the
items are listed in the Technical Specification Sheet furnished with the
handing-over documents.
2.2 STANDARD FITTINGS
2.2.1 As per BS:171-1978, Pt1 & BS:7821 Pts 1-3 the Standard Fittings as
listed below, are the minimum requirements for the safe & correct operation of
a transformer.
a) Diagram & Rating Plate

b) Off-Circuit Tapping Selector
c) Oil Level Indicator
d) Oil Drain Valve
e) Outdoor Bushings / Weather-proof Cable Box
f) Earthing Terminals
g) Lifting Lugs
h) Jacking Pad
i) Thermometer Pocket
j) Breather Pipe with Air-Vent for ratings below 2500kVA
k) Breather Pipe with Dehydrating Breather for ratings above 2500kVA
l) Conservator for ratings above 11kV & 2500kVA
2.3 OPTIONAL FITTINGS
2.3.1 As per customers specification, the Optional Fittings as listed below

are provided for the additional protection operation of a transformer.
a) Oil Temperature Indicator

b) Winding Temperature Indicator with WTI CT
c) Gas & Liquid Operated (Buchholz) Relay
d) Explosion Vent / Pressure Relief Device
e) Disconnecting Chamber
f) Oil Filter Valve
g) Rollers or wheels
h) De-hydrating Breather for rating below 2500kVA
i) Conservator for ratings below 11kV & 2500kVA
j) Marshalling box for all wiring
9
3.0 GENERAL INFORMATION
3.1 ARRANGEMENT FOR TRANSPORT
3.1.1 Each oil-filled transformer is thoroughly dried-out before dispatch. Oil,

whether in the transformer tank or in separate drums, is thoroughly filtered,
when dispatched.
3.1.2 Parts that are liable to be damaged in transit are removed and
dispatched in separate cases along with the transformer. Accessories like
radiators, bushings, explosion-vent, dehydrating breathers, buchholz relays,
temperature indicators, pressure relief device, conservator, etc., will be
removed before dispatch.(higher power ratings). Distribution transformers
can be shipped complete in standard shipping container.
3.1.3 Weatherproof blanking plates are provided where necessary. Due to

transport limitation and for convenience of storage/handling at site, if a unit
can be dispatched completely assembled then the transformer is usually
dispatched from the factory with oil covering the core & winding along with the
balance oil in separate sealed drums and the other accessories / fittings in a
separate packages.
3.1.4 The transport oil quantity and the parts removed for transport are
generally indicated in the G. A. Drawing or the Packing List furnished along
with the unit during delivery / handing-over of the equipment. Re-assembly of
these parts should be carried out such that the tank is opened to the
atmosphere for a minimum time.
3.2 RECOMMENDED INSPECTION
3.2.1 Transformers are properly packed & dispatched by suitable transport

up to destination. In spite of all care being taken during dispatch, the
equipment can get damaged during transit and any consignment should be
checked after delivery at site.
3.2.2 Immediately on arrival at site, any transformer should be examined for

any sign of external damage in transit with particular attention to;
dents / cracks in tank side-walls, covers, radiators, etc.

damage to protruding fitting such as bushings, valves, sight glasses
etc.
loose bolts / screws / clamps
oil leakage, particularly along welded joints & gaskets
The various packages should be checked against the advice notes. Any
discrepancy from the advice notes should be immediately reported to the
Insurance Underwriters, and to the Transport Contractors, used for
transportation by the Supplier, particularly where damage has occurred in
transportation. Claims can then be lodged with transport contractor and / or
insurance underwriters as required.
10
3.2.3 Unless there is reason to suspect internal damage, the tank cover
should not be opened and no attempt to lift Core & Coils clear of tank should
be made. Internal inspection should be carried out to the maximum possible
extent via inspection covers provided.
3.2.4 It is ESSENTIAL that loss / damage of any components / parts / paint

works or shortage / leakage of oil or any signs of tampering to be reported to
supplier immediately. And all possible evidence such as photographic / video
clips, copies of documentation / declaration from transport contractors shall be
submitted.
3.3 UNLOADING & HANDLING OF TRANSFORMER AT SITE
3.3.1 The transformer should be unloaded by means of a crane or suitable

lifting device of sufficient capacity (For weight details, please refer the Rating
& Diagram Plate). Always use lifting mechanisms, crane, chain pulleys, etc. of
adequate capacity. Use of any under capacity lifting mechanism or
accessories could result in severe damage to the transformer, lifting
equipment and possibly personnel involved in handling the transformer.
3.3.2 For lifting, suitable lugs are provided on the cover & on sides of tank.
Lifting lugs on the sides of tank are for lifting the COMPLETE unit, whereas
the lugs provided on the tank cover must only be used for lifting the cover.
3.3.3 Jacking pads are provided to lift the transformer with jacks. Jacks
should NEVER be placed under any valves or radiators. Do not use low
capacity lifting jacks.
3.3.4 Skid type under base channels are provided on the bottom of the
transformer, having towing holes for pulling & mounting holes for foundation of
transformer. For heavy transformers, the under base is equipped with rollers
allowing the unit to be manoeuvred into final position and then anchored.
3.4 STORAGE
3.4.1 Accessories / Fittings dispatched separately from main consignment

are usually packed in case/crate, although certain items like conservator are
sometimes dispatched without packing. All items as received should be stored
in a dry and covered place provided there are no signs of damage or rough
handling.
3.4.2 If oil received in drums is not to be used immediately, the drums should
be stored in a covered space where the temperature variation is minimum. If it
is necessary to store the oil outside, adequate protection must be provided at
all times. Drums should not stand on end but should be placed on their sides
in semi horizontal (lying) position with the bottom tilting at 45 downwards.
3.4.3 After arrival at site, it is desirable to erect and commission the

transformer with minimum delay. In case this is not possible, the transformer
should be fitted with conservator, dehydrating breather, etc. and filled with oil.
The condition of desiccant (enviro-gel) must be checked periodically,
particularly during warm and wet periods.
11
3.4.4 Indoor type transformer must be protected from the weather. Outdoor
units may be stored outside, in a warm area, if possible, protected from the
prevailing weather.
3.4.5 Whenever possible, it is recommended that the transformer is
energised even at a low voltage so that the oil temperature is about 10 to
15C higher than the surrounding ambient temperature.
3.4.6 Heaters for marshalling box, cable box, etc., should preferably be kept
energised to avoid possible internal condensation / deterioration of the
internal components.
12
4.0 INSTALLATION
4.1 PRECAUTIONS
4.1.1 Workmen accessing the interior of a transformer tank should empty

their pockets of all loose articles. Any spanners or other tools used should be
securely tied with a tape / thread and attached at tank top, so that they can be
recovered, if accidentally dropped into the tank.
4.1.2 Fibrous cleaning materials MUST not be used. The presence of loose
fibre suspension, in insulating oil, can reduce its insulating properties. If any
cleaning or wiping is necessary this must be done with clean and dry soft non-
fluffy cloth only.
4.1.3 All accessories / fittings / components dispatched separately should be

thoroughly cleaned inside and outside before being fitted. Rusted internal
surfaces should receive special attention.
4.1.4 Insulating oil is inflammable and, under certain circumstances in a

confined space, may become explosive. Naked lights & flames must NEVER
be used adjacent to an oil filled transformer.
4.1.5 Air drawn into the transformer through semi-tight joints or along with
the oil may be drawn into the windings thus reducing the insulation. To
prevent this, all joints / covers in any extended oil pipe work must be air tight.
4.1.6 Insulating oil and the cellulose based solid insulation, normally used in
transformer, absorbs moisture easily, particularly when cold. Condensation /
damp hazards can be caused if the interior of a tank is exposed to
atmosphere. By taking adequate precautions this can be avoided / minimized,
by circulating warm, dry de-aerated oil through it until its temperature is 5C to
10C above ambient. This should be done before allowing external access to
the interior of the tank. The warm oil should be circulated all the time the
transformer is open to atmosphere.
4.1.7 Under normal circumstances, it is NOT necessary to access the

internal parts of the tank. Also, all the required tools / tackles / instruments are
generally not available at site for the proper handling / access.
4.2 LOCATION AND SITE PREPARATION
4.2.1 No special foundation is necessary to install a transformer except a

levelled floor base of sufficient strength to support the weight and prevent
accumulation of water.
4.2.2 A foundation including special oil drainage/collection facilities in case of

fire and emergency is strongly recommended for large transformers.
4.2.3 The transformer should be positioned on the foundation so that easy

access is available all around to access the diagram plates, thermometers,
valves, oil gauges, etc., to be easily reached or read.
13
4.2.4 Adequate electrical clearances are also to be provided from various
exposed live parts of the unit to any earth point. (Ref.: Statutory & Regulatory
Requirement on Electrical Clearance in Air.)
4.2.5 Any transformer should always be separated from other transformer,

reactors and any other such heat generating equipment. Transformer should
be well placed sufficiently away from all walls / partitions to permit free
circulation of air / ventilation.
4.2.6 Rollers, if fitted, shall be suitably clamped / locked to prevent any

movement of transformer from its designated position in relation with HV / LV
Side terminations.
4.2.7 External power conductors, power cables, control cables, earthing

conductors, etc., shall be so positioned / supported such that no pressure is
exerted on the transformer bushing terminals / cable box.
4.2.8 Naturally cooled transformers depend entirely upon the circulation of

air to assist in removal of all heat generated due to internal losses. For indoor
installation, therefore, the room must be well ventilated so that heated air can
escape and be replaced by fresh cool air. Air inlets/outlets should be sufficient
to allow adequate air to cool the unit. The inlets shall be near the floor and
outlets shall be near the ceiling. If necessary, exhaust fans can be installed to
assist the process.
4.2.9 If rollers are not fitted, a level concrete plinth with bearing plates /
mounting channels of sufficient size/strength can be used for outdoor
transformers. To prevent rust formation, it is essential to avoid air/water
between plinth and the transformer base. If required, bitumen or such similar
substance shall be used on the transformer base for weather-proof protection.
4.2.10 For small capacity pole mounted type transformer, proper care must be
taken that all the supporting poles / structures, mounting brackets / clamps
are of suitable materials & strength to bear both the static & dynamic weight of
the transformer.
4.2.11 Suitable provision shall be made for all non-current carrying metal parts
used for the transformer support / base such that they can be earthed,
preferably at two points.
4.3 INSULATING OIL
4.3.1 Oil acts as both insulant & coolant. Cooling radiators fitted with the tank
will be either fixed type or detachable type radiators for ONAN (Oil Natural Air
Natural) cooling.
4.3.2 Only the insulating oil supplied along with the transformer shall be used
for filling-up or topping-up the transformers. Any other oil not supplied by PDT
shall be specifically approved by PDT to ensure that the original specification
is maintained. THE MIXING OF OILS FROM DIFFERENT SUPPLIERS IS
NOT RECOMMENDED REFER 4.3.3.
14
4.3.3 Oil from different sources may not completely mix together and may
remain separated in layers. There may be a greater tendency to form acidity
or sludge in a mixture of oil from two different sources than in a mixture of oils
from a single source.
4.3.4 Oil supplied with the transformer is a pure hydro-carbon mineral oil
conforming to BS:148-1984 for insulating oil. When exposed, oil can be easily
contaminated. It is very important to keep the oil free from contamination,
moisture, etc. All equipments / apparatus to be used for handling the oil
should be first cleaned and flushed with clean insulating oil. Particular
attention must be paid to cleanliness of bungs / plugs / stopper, valves and
other such places, where dirt or moisture tends to collect.
Note: (CONTAMINATED / USED OIL MUST BE DISCARDED ONLY IN
ACCORDANCE WITH THE ENVIRONMENTAL REGULATIONS)
4.3.5 Oil must NOT be emptied / spilled / handled near naked lights or flame
- the oil vapour released is inflammable.
4.3.6 Small quantities of moisture (particularly with presence of fibres or

dust) lower the dielectric strength of the oil. Oil containers taken into a warm
room / area must not be opened until the entire body has attained the same
room temperature. This will reduce risk of condensation / moisture entering
the oil.
4.3.7 For sampling, glass containers with glass stoppers are to be preferred
over the metal types which are susceptible to contamination by dirt, etc. Wax
should not be used for sealing the oil sample bottles. However, the stopper
can be covered by a pack of dehydrating gel tied in a piece of cloth.
4.3.8 Flexible steel hose is best for handling insulating oil, some kinds of
synthetic rubber or PVC hoses are also suitable but only those known to be
satisfactory shall be used. Ordinary rubber hose should NOT be used - oil
dissolves the sulphur from the rubber and is thereby contaminated. Any hose
used for handling oil must be clean and entirely free from loose rust or other
dirt. Cleanliness is essential as even small amounts of dirt and water will
affect the accuracy of test results.
4.3.9 ALWAYS disconnect transformer from electricity supply before

lowering the oil level.
4.3.10 In general, oil from a reliable source complying IEC:60296 / IEC:60422

/ BS:148 / BS:5730 and, in addition, meeting the following requirements is
approved to use.
Break-Down Voltage (BDV) of the oil above 50 kV for 1 minute.

Resistivity of the oil above 500x1012 ohm/cm at 27C & above 13x
1012 ohm/cm at 90C.
Tan-Delta value of oil below 0.005 at 90C.
Moisture content of oil below 10 ppm
15
4.3.11 Samples of transformer oil, taken from the bottom of the tank /
transported oil drum, when tested & found with a dielectric strength below
30kV (rms) during the one minute withstand time, in a standard test cell
(13mm spheres 4mm apart) the matter must be reported to supplier along
with insulation resistance values between various windings & earth. If the
dielectric strength is between 40 & 50kV (rms), the oil should be treated to
improve the dielectric strength.
4.3.12 Cloudiness of oil is due to suspended solid matter such iron oxide or
sludge or moisture. The presence of moisture can be detected by Crackle
Test, whereby when a red-hot iron pipe is immersed in the oil sample, crackle
sound will be heard due to sudden evaporation of moisture inside the oil.
4.3.13 An acid smell indicates the presence of volatile acids, which causes
corrosion and renders the oil unsuitable for treatment. Recommended acidity
limits are;
Below 0.5mg of KOH per gm of oil no action required

Between 0.5 to 1.0 mg of KOH per gm of oil may be treated / filtered
Above 1.0mg of KOH per g of oil to be re-conditioned / discarded
Acidity above 1.0mg of KOH per gm of oil is also indicates the
presence of sludge, which chokes the oil circulating ducts resulting in
high winding temperature. The amount of sludge may be detected by
dilution of oil with normal heptane.
4.3.14 A petrol-like or acetylene odour may indicate a low flash-point due to

prolonged high temperature because of an internal fault. A flash-point below
130C indicates unsatisfactory condition and in that case necessary action
shall be taken to assess the cause and take remedial steps or oil
replacement.
4.3.15 Oil takes up moisture readily and its condition should always be
checked before use. Oil of a muddy colouration is certain to be wet. Water
and water saturated oil are both heavier than dry oil and sink to the bottom of
any container. Oil samples should, therefore, be allowed to settle for 4 to 6
hours - in case of small transformer or drums, and for 10 to 12 hours - in case
of large transformer. In general sampling, testing & treatment of oil shall be as
per BS:5730-1979.
4.3.16 Samples from tank: Dirt adhering to the valve or plug is to be removed
ensuring valve is VERY clean, and then a quantity of oil is allowed to flow into
a separate container before collecting sample for testing. Samples should be
collected in clear glass bottles, thus any water present in the oil will settle to
the bottom and be clearly visible. Only use bottles with glass stoppers for
sampling.
4.3.17 Samples from oil drum: Drum should first be kept standing vertically
upwards for at least 24 hours. The bung area should be cleaned. A clean
glass or brass tube long enough to reach to within 12 mm of the base of the
drum should be inserted, keeping the upper end of the tube sealed with the
16
thumb whilst doing so. The thumb should be removed, allowing oil to enter the
bottom of the tube. The tube is then resealed and an oil sample withdrawn
from the drum. The first two samples should be discarded. Further samples
shall be collected in a clean bottle.
4.3.18 Testing: The oil after filtration should meet the requirements as laid
down above. However, to establish the preliminary condition of the oil, the
Break-Down Voltage (BDV) Test shall be carried out as stipulated in
IEC:60296 and results noted.
4.3.19 Before putting the oil into the tank, it should be tested and comply with
specification as per IEC:60296 / clauses above. IF the oil does not meet the
requirements, it should be processed and should be used ONLY when it
meets the specification.
4.3.20 When filling it is preferable to pump the oil into the bottom of the tank
and that an oil drying / filtering device is interposed between the oil pump and
the tank reducing to a minimum any air entry into the tank with oil.
4.3.21 Used oils shall NEVER be mixed with the existing oil.
4.3.22 Oil shall be filled up to the marked level, indicated on the oil level
gauge corresponding to the oil temperature at that time.
4.3.23 After the oil filling, ensure that all the air release plugs, petcocks and
valves are tightly closed and that dehydrating breather is provided with oil
seal.
4.3.24 Oil should be allowed to settle at least for 12 hours - in case of small
transformer or for 24 hours - in case of large transformer. After which, again
all air release plugs, petcocks and valves shall be open till the oil flows out,
allowing the escape of any trapped air, after the oil has completely settled
down.
4.4 GASKETS AND JOINTS
4.4.1 Transformer sealing gaskets are made of neoprene bonded or

rubberized cork. When supplied loose, generally have no holes, however, in
some cases, gaskets are supplied in pieces cut to size and shape as required
as straight, angled, or U shaped pieces from which complete gaskets can be
built.
4.4.2 When assembling / joining individual pieces use scarf joints only.
Assembled portion should be located away from corners and bolt holes, and
should be evenly bonded. Holdite solution is used as an adhesive for joints.
4.4.3 To make a gasket joint, first clean all metal surfaces ensuring freedom
from oil, rust, scale, etc. Using one of the flanges as template, mark and
punch the necessary bolt holes in each gasket. Insert and evenly tighten each
bolt so that uniform pressure is exerted on the gasket until the gasket is
compressed to approx. 2/3 of its original thickness. If proper care is taken - in
making and handling joints or gaskets, it is possible to break / re-make a joint
several times, using the same gasket.
17
4.4.4 Gaskets are best stored in hermetically sealed containers in a cool
place. They must be protected from damp, oil and grease.
4.5 TERMINALS / BUSHINGS
4.5.1 Bushings are usually removed for transport and the bushing holes
blanked off. Before fitting, bushings should be examined for damage or cracks
which may have occurred during transit. They should be cleaned with a dry
non-fibrous cloth.
4.5.2 Bushing should be assembled with their adapters, if supplied, using the
proper gaskets for the various joints. When clamping the bushings to the tank,
care should be taken to ensure that an even pressure is obtained on the
flange of the porcelain and its gasket by tightening the diagonally opposite
nuts alternatively.
4.5.3 The external line termination / connection to all types of bushings

should be flexible to ensure that there is no strain exerted on the bushings
because of line movement such as swing, expansion, contraction etc.
4.5.4 If arcing horns are fitted, the gap shall be checked and adjusted as per
the drawing.
4.6 CABLE BOXES
4.6.1 Compound filled cable box:
a) If cable boxes are supplied separately, they should be first fitted on the
tank with the proper gasket joints. After making the suitable end-
termination and connection with the terminal bushings, the box should
be filled, up to the correct level, with suitable filling medium. Hot
insulating compound shall not be poured directly on the porcelain of
insulator. Before energising the transformer, the filling medium should
be allowed to settle-down for 24 hours to check against possible
leakage.
b) After the filling, the filling holes should be closed with weatherproof
plug with copper fibrous gaskets / sealed with suitable grade of
bituminous compound which will not crack during cooling (e.g. Grade
Class-3 of BS:1858).
c) The cables should be supported separately to ensure that no-undue
strain is exerted on the porcelain bushing terminals in the cable box.
4.6.2 Air filled cable box (for Heat-Shrink / Push-On / other such
Termination):
a) Cables shall be terminated on copper bus-bars provided in a cable box

and termination shall not exceed the number of holes provided. In other
words NO extra holes may be made in bus-bars at site.
b) The cable shall be clamped / supported by suitable cable glands. Care
shall be taken to ensure minimal stress on the bus-bar.
18
c) Necessary identification of phases is provided inside the cable box.
After completion of termination, insulation tape can be applied on each
bus-bar.
4.7 CONSERVATOR (If SUPPLIED)
4.7.1 As the temperature of insulating oil increases or decreases, there is a

corresponding rise / fall in the oil volume. To allow for this, an expansion
vessel (conservator) can be connected to the tank to limit the amount of air to
be in contact with insulating oil.
4.7.2 While assembling the conservator, ensure that internal surface, all
openings, pipe works, valves, etc, are clean & free from moisture and all
gasket joints are oil-tight.
4.7.3 Prismatic / Plain hardened glass type oil gauge, if fitted with the
conservator, is generally marked with calibrated level to show cold oil level at
15C temperature.
4.8 DEHYDRATING BREATHER (If SUPPLIED)
4.8.1 Plain pipe breather is generally sealed with cap for transit purpose and
the same should be removed ONLY during commissioning.
4.8.2 Alternatively, a Dehydrating Breather should be fitted to ensure that air

entering the tank during breathing is dry thus preventing insulation loss of oil
due to internal condensation.
4.8.3 A Dehydrating Breather, usually Envirogel (self indicating silica-gel) or

Blue Silica-Gel, is dispatched as loose item to prevent unnecessary
accumulation of moisture via two-way valve / oil-seal cup of the breather
during transit.
4.8.4 In case of Envirogel, for visual indication of degree of saturation, the

silica-gel is impregnated with suitable non-toxic dye. Envirogel in YELLOW /
ORANGE colour, indicates the ACTIVE state or readiness to absorb moisture
and when in GREEN colour, indicates the INACTIVE / saturated state or
presence of moisture or inefficient to absorb further moisture.
4.8.5 In case of Blue Silica-Gel, for visual indication of degree of saturation,

the silica-gel is impregnated with Cobalt Chloride [Class-2 Carcinogen]. When
Silica-Gel is a BLUE colour, this indicates the ACTIVE state or readiness to
absorb moisture and when it has become PINK its unable to absorb further
moisture.
4.8.6 To activate the saturated silica gel, heat it in a pan / oven at 120-
130C temperature until the original colour is regained within 2 to 3 hours,
otherwise always replace with new gel and discard the used gel.
19
4.8.7 When the oil-filled transformer is fitted with the de-hydrating breather
ALWAYS reactivate / replace the desiccant once the colour indicates the
saturated state, irrespective of whether the transformer is energised or not.
4.8.8 The plug sealing the top of the breather should be removed and
connected to the associated pipe-work. The oil cap at the bottom of the
breather should be removed, filled with insulating oil up to the mark and the
cap replaced. The oil seal ensures that breather does not absorb moisture
when the transformer is not breathing.
4.8.9 When refilling the desiccant, do not expose the same to the
atmosphere for an undue length of time, otherwise it will start absorbing the
moisture and thus impair its purpose. Also, after fixing the breather, ensure oil
seal is filled with oil up to the mark.
4.9 EXPLOSION VENT / PRESSURE RELIEF DEVICE (IF SUPPLIED)
4.9.1 The explosion vent flange on the tank cover is blanked during dispatch.
This should be removed and the explosion vent pipe fitted with suitable
diaphragm and air-tight gasket joints. And the top blanking plate should not be
removed till the oil level inside the transformer is above the tank cover.
4.9.2 For some transformers, the space above the oil in the explosion vent is
usually connected by a pipe to the top of the conservator to equalize the
pressure & vent it to the atmosphere through a breathing device.
4.9.3 For transformers supplied without such equalizing pipe, an air-cock is

fitted at the top of the explosion vent pipe, which must be opened (to vent)
when the tank is being filled with oil and then closed again.
4.9.4 If an over-pressure inside the tank causes failure of either / both

diaphragms, renew the same immediately.
4.9.5 As an alternative a spring loaded device (Pressure Relief Device),

which resets itself immediately on removal of overpressure, can be supplied.
This may also be fitted with a mechanical indicator for visual indication to
show operation.
4.9.6 A single set of contacts is provided for trip signal. These terminals are
clearly marked for function and polarity (locked during shipment), which
should be set at service position before energising the transformer. When
making the connection from these terminals in conduits, ensure that no
condensation can drain into the terminal box.
4.10 BUCHHOLZ RELAY (IF SUPPLIED)
4.10.1 The buchholz (gas / liquid operated) relay is connected in the pipe work
between transformer tank and conservator. If a valve is fitted to isolate the
conservator, the buchholz relay is usually on the transformer tank side of the
valve.
4.10.2 Under normal condition the relay is full of oil. As generally known, most
types of faults occurring within oil filled transformers are accompanied by the
20
generation of gas by the oil due to liberation of heat. Such generated gas gets
accumulated in the relay thereby operating the float / flap switches.
4.10.3 With an incipient fault, gas is produced at a very slow rate and the
upper float (alarm) switch will operate after a specified volume of gas has
collected. The upper float (alarm) switch will also indicate the low oil level of
the conservator.
4.10.4 When a major fault occurs, the gas is produced rapidly resulting in
sudden surge of oil up to the conservator thereby operating the lower float
(trip) switch. The lower float (trip) switch will also indicate the drained oil level
of the conservator.
4.10.5 To ensure successful operation of the relay, the pipe work on either
side of the relay and the relay itself, are all set at the same angle (2-5 to the
horizontal for single float relay and 3-7 to the horizontal for double float
relay). A machined surface is provided on the housing of the relay to check
the level. And the arrow shown on the relay should point towards the
conservator.
4.10.6 The alarm and trip terminals are clearly marked for function and
polarity (locked during shipment), which should be set at service position
before energising the transformer. After which check that the operating floats /
flaps are free. When making the connection from these terminals in conduits,
ensure that no condensation can drain into the terminal box.
4.10.7 In service, the top petcock should be kept closed. Before energising
the transformer, all air which may have collected in the relay should be
released through the petcock.
4.11 TEMPERATURE INDICATORS (IF SUPPLIED)
4.11.1 The Oil Temperature Indicator (OTI) and Winding Temperature

Indicator (WTI) work on either the liquid expansion or bi-metallic principle and
provide indication of top oil and average winding temperature via dial type
indicators. In all cases, the indicators shall be mounted vertically for best
accuracy of readings.
4.11.2 The thermometer bulb / probe is connected by capillary tube to the

indicator. The bulb / probe shall be fitted into the thermometer pocket
provided in the transformer main tank cover near the hottest oil region. Before
fitting the bulb / probe, thermometer pockets should be part filled with
transformer oil.
4.11.3 WTI is same as OTI except for the current feed circuit from CT to
heating element either on the thermometer pocket or in the instrument itself.
4.11.4 Normally the current feed to WTI is provided from a CT at one phase of
the LV winding. Such CT has suitable Ratio to feed required current to heat
the heating element. This additional temperature component from heating
element together with the prevailing top oil temperature gives the average
21
winding temperature seen at WTI. The CT connection to WTI shall be made
carefully (Ensure that CT secondary is not open circuit at any time).
4.11.5 The copper capillary tube is protected by flexible steel tubing, which is
strong enough to withstand normal handling. It should NOT, however, be bent
sharply or be twisted. To prevent sagging, tube shall be supported by clip
along it entire length. And the excess length, if any, can be rolled spirally and
on no account it should be cut.
4.11.6 OTI and WTI are provided with a re-settable maximum pointer and
mercury float limit switches or bi-metallic switches for electrical alarm & trip
indication, as specified by the customer.
4.11.7 OTI and WTI may also be provided with Thermistors, whose resistance
varies with temperature, for temperature reading at temperature detector
located at a remote panel.
4.11.8 Before installing the instruments, the accuracy can be checked by

dipping the bulb / probe in a hot oil or water bath and checking the instrument
readings against a standard calibrated thermometer. The indicator readings
should be allowed to steady (inherent time lag) and the readings shall be
accurate within 1C.
4.11.9 If required, alarm / trip switches shall be adjusted to make contact at

the set temperatures as per site conditions i.e. ambient temperature, loading
conditions, etc.
Recommended Maximum Temperature Setting are;
a) Oil Temperature Indicator 85C for Alarm 95C for Trip

b) Winding Temperature Indicator 105C for Alarm 115C for Trip
4.12 COOLING RADIATOR
4.12.1 If shipped separately, all the radiators, pipe work and headers should
be cleaned and flushed with clean dry oil before fitting. These should be
assembled as shown on the Outline/G.A drawing.
4.12.2 During assembly care must be taken that all the gasket joints between
radiator and the transformer tank are air-tight and the flanges are evenly
fitted.
4.12.3 After assembly of radiators, the shut off valves provided at top &
bottom should be opened. This will allow the radiators to be filled with clean
and dry transformer oil. Air should be released from top of the header of each
radiator.
22
4.13 CURRENT TRANSFORMERS (IF SUPPLIED)
4.13.1 Before energising the transformer, secondary circuit of any CT fitted

MUST always be short-circuited or connected with the load circuit. When CT
primary is energised with secondary winding open, excessive voltage will
develop across the secondary circuit and damage the CT or become a safety
hazard if touched.
4.14 EARTHING CONNECTION
4.14.1 The tank should be permanently and effectively connected to earth by

means of flat / flexible conductor of suitable size & materials (galvanised steel
/ copper / equivalent) terminated on earthing terminals / pads provided at the
bottom of the tank, cable box, marshalling box, switch gear box, etc. Refer to
BS:CP1013-1965
4.14.2 Earthing connection(s) with a good low resistance is/are essential for
adequate protection against electrical faults. All the earth connections should
be of sufficient physical size to carry the line current for 30 seconds.
4.15 PAINTWORK
4.15.1 All metal parts are properly cleaned, suitably surface treated and given
three coats of high quality paint before dispatch from the works. The first,
which is applied to the neat metal surface, is a primary coat, followed by an
intermediate coat and then a final finishing coat as per relevant specification.
4.15.2 Normally the final finishing coat will be dark grey, either Colour Chart
Shade No.: 632 or 631 of BS:381C, unless specified differently by the
purchaser.
4.15.3 If the paint-work has been damaged during transit or erection, touch-up
painting should be carried without delay to avoid any possible rusting of metal.
4.15.4 For exact detail of colour shade, refer general arrangement drawing or
technical specification furnished with hand-over documents. If no information
available, suitable paints shall be procured in consultation with product
literature of any reliable paint suppliers like Shipley, Jenson & Nicholson,
etc.
4.15.5 Failure to attend to paintwork damage will result in considerable

deterioration of metal surfaces of equipment during storage or service.
4.15.6 For further guidance, the following information is provided;
a) Surface to be repainted should be thoroughly cleaned to remove any

grease/rust.
b) Dry Film Thickness (DFT) shall be 25 to 35micron for the first coat, 50
to 60micron after the second coat and 75 to 80micron after the finishing
coat.
c) For normal environment, high quality alkyd resin based paint is
recommended. And for polluted environment, paint as recommended
by paint suppliers shall be used.
23
4.16 COMPLETION OF OTHER INSTALLATION WORKS
4.16.1 Any work such as secondary wiring from various Phase CTs / Neutral
CT, wiring of various alarm / trip contacts from various accessories of the
transformer to Marshalling Box, Control Gear Box, if/as required shall be
completed at site.
4.16.2 All the scheme wiring, relay settings, functional checks, etc., should be
completed before the transformer is released for commissioning into service.
24
5.0 COMMISSIONING
5.1 PURPOSE
5.1.1 After the satisfactory completion of installation, the following pre-

commissioning checks and tests on instruments must be performed before
putting the transformer into service. Prior to commissioning work, for specific
help and information on the accessories supplied, refer to the manufacturers
instruction booklet / product catalogue, etc., furnished with the handing-over
documents.
5.2 COMMISSIONING TESTS
5.2.1 Insulation Resistance (IR) Test:
a) Before starting this test all the power terminal bushings should be
thoroughly cleaned with a dry clean piece of cloth.
b) During IR test, no external power lines / cables, lightning arresters,
neutral earthing, etc., should be in the power circuit. And ensure that
transformer is completely isolated at HV & LV sides and all non-current
carrying conductors are earthed.
c) At all the tap positions, IR values of windings to earth & between
windings shall be measured with designated insulation tester of
suitable ratings and readings noted.
Between HV Winding and Earth use 5000V or 2500V Insulation
Tester (Megger)
Between HV and LV Winding use 5000V or 2500V Insulation
Tester (Megger)
Between LV Winding and Earth use 1000V or 500V Insulation
Tester (Megger)
d) IR values obtained should be similar to those indicated in the
manufacturers test report, furnished with the handing-over documents.
In humid weather, IR values obtained may be lower due to
condensation on the terminal bushings.
e) If IR values are very low and unacceptable, then it may be necessary
to filter the oil / dry-out the winding till the insulation reaches
satisfactory values.
5.2.2 Break-Down Voltage (BDV) Test:
a) Oil samples from tank bottom, tank top, radiator, etc. shall be carefully
taken and tested for BDV value, as per clause 4.3 of this manual.
b) BDV value of oil should be more than 50kV(rms) for 1 minute in
standard test cell.
c) If BDV value is very low and unacceptable (30kV(rms) or less for 1
minute, then it may be necessary to dry-out & clean the oil till the
insulation reaches satisfactory values.
Note: For very low IR values and low BDV values, it is recommended
to contact suppliers or manufacturer for suitable recovery procedure
based on available facilities at site.
25
5.2.3 Voltage Ratio Test
a) Apply 3-Phase, 433V AC supply on the HV side and the Voltage Ratio
at all tap positions can be derived using suitable precision voltmeter
connected to the LV side. A ratio meter, if available can be used for a
more accurate measurement.
b) The Ratio values obtained should be similar to those indicated in the
manufacturers test report, furnished with the handing-over documents.
5.2.4 Winding Resistance Measurement Test
a) Winding Resistance of every phase of each winding should be

measured using suitable DC Resistive Bridge or similar.
b) Winding Resistance values obtained should be similar to those
indicated in the manufacturers test report, furnished with the handing-
over documents.
5.2.5 Marshalling Box Scheme Check
a) All the auxiliary wiring from various accessories to marshalling box

shall be checked with marshalling box scheme drawing furnished with
the handing-over documents.
b) During testing of accessories like buchholz relay, etc., operation of all
the alarm / trip contacts shall be checked at marshalling box terminal
blocks ensuring both operation and wiring are checked correct.
5.2.6 Buchholz Relay Test
a) Relay operation for alarm and trip contact shall be checked by injecting
air inside the relay through test petcock. Injected air collected inside
the relay allow the alarm float / flap & trip float / flap to fall thereby
operating their respective switch.
5.2.7 Temperature Indicator Test
a) Indicators operation for alarm and trip contact shall be checked by

manual stimulation.
5.2.8 Off-Circuit Tap Selector (OCS)
a) During shipment, the OCS has not been separated from the
transformer so it is not necessary to recheck the internal connections of
tapping and internal mechanism.
b) Means of protecting the OCS from unauthorised operation is provided
by using pad locking arrangement at designated tap position.
26
5.3 SENSIBLE ADDITIONAL CHECKS
5.3.1 BEFORE SWITCH ON, ENSURE that
a) All the Oil Shut-Off Valves are OPEN and Draw-Off Valves are
CLOSED.
b) All Thermometer Pockets are near filled (85%) with oil.
c) Oil is at correct level in the Bushings, Conservator, etc.
d) Desiccant colour in breather is blue for blue silica-gel or yellow /orange
for envirogel.
e) Earthing Connection of Main Tank, Neutral Bushing, Marshalling Box,
Control Gear Box, Cable Box, Arcing-Horn, etc., are correctly made.
f) Bushing arcing horn gap is set correctly.
g) All CT Secondary Circuits are closed.
h) All Air-Release Plugs of Main Tank, Radiator, Conservator, Buchholz
Relay, Bushings, etc., are free of air pocket / bubbles.
Note: After Oil-Filling or Before Commissioning, AT LEAST 12hrs
should be allowed for the oil to settle-down and air is released from all
points at 2 hourly intervals.
5.3.2 It is recommended that the transformer is initially energised at NO-

LOAD only and checked for any abnormalities for the next 6 to 8 hours.
5.3.3 AFTER SWITCHING on no-load, if the Primary Side Circuit Breaker is

tripped, investigate the cause thoroughly and re-energise the transformer
ONLY AFTER ensuring that the fault is properly cleared.
5.3.4 If satisfactory (transformer on No-Load) then apply load gradually and

observe for any abnormalities for the next 6 to 8 hours.
5.3.5 If the transformer is satisfactory on-load up to 50% for the first 4-8
hours, shut-down the transformer and ensure that all air-release plugs of tank,
radiator, conservator, buchholz relay, bushings, etc., are free of air pockets
which might have developed during initial loading.
27
6.0 MAINTENANCE
6.1 General
6.1.1 If a transformer is to give long and trouble-free service, it should

receive a reasonable amount of maintenance, which consists of regular
inspection, testing and reconditioning when necessary. Records should be
kept giving details of any abnormalities during service and also of any periodic
test results taken. This demonstrates compliance with the general
requirements of ISO:9000.
6.1.2 MAIN OBJECTIVE OF ANY MAINTENANCE IS TO PRESERVE THE

ORIGINAL PROPERTIES OF THE MATERIALS IN GOOD CONDITION.
Moisture, dirt, excessive heat / over-loading, mishandling, etc., are the main
causes of INSULATION deterioration.
6.1.3 No maintenance work should be done on the transformer, unless all

the external circuits are disconnected / made dead and that all the windings
are solidly earthed.
6.2 INSULATING OIL
6.2.1 Oil is a VERY IMPORTANT liquid being used both as a coolant &
dielectric (insulant) in the transformer and thus keeping the oil in good
condition will prevent deterioration of the paper & other such solid insulation
materials immersed in it.
6.2.2 IEC:60422 - Maintenance of Insulating Oil gives recommendations in

detail for the preservation of insulating oil. A few short notes on the subject
are given as below;
a) Oil level should be checked at frequent intervals and any excessive
leakage of oil must be investigated thoroughly. There may be a slight
loss of oil by evaporation; this need not cause concern if the tank is
topped up at regular intervals.
b) All minor leaks or sweating should be repaired as quickly as possible.
c) Oil shall be topped-up as per instruction of this manual. It is once again
emphasized that any new oil to be added shall preferably be from the
same source as the original oil. New oil from a different source may be
added as make-up only but not exceeding about 10% of existing oil
volume. In this case, suitable records should be kept.
d) Samples of oil should be tested at regular intervals and results are
recorded.
e) Dielectric strength alone does not give a true indication of oil condition.
If dry, even highly deteriorated oil can give a high dielectric strength.
f) Normal oil filtration method can maintain the dielectric strength only,
but does not give indication of the deteriorated condition of the oil. It is
NOT advisable to rely solely on the dielectric strength of the oil by
periodic test, without verifying its chemical composition. Reconditioning
by centrifugal separation or filtration does not remove the acidity from
oil but will remove moisture, sludge, dust, dirt, etc. and will tend to
retard the process of deterioration. Filtration with Fuller Earth will help
28
to reduce acidity in oil and in addition improve the resistivity value of
the oil.
g) If the dielectric strength is below 30kV(rms), the oil should be
reconditioned by passing it through either a centrifugal separator or a
filter. After reconditioning, the dielectric strength should be such that oil
can withstand a minimum of 40 kV(rms).
h) If acidity value is 0.5 to 1.0 mg KOH per gm of oil, it is recommended
that the oil be kept under observation. If the acidity is increasing
rapidly, or exceeds 1.0 mg KOH per gm of oil, the cover should be
removed to ascertain the condition of the interior of the tank and of the
core & windings. Oil is then be treated or discarded, if sludge or
corrosion is evident. Advice should be obtained from the suppliers.
6.3 INTERNAL TRANSFORMER CORE & WINDINGS
6.3.1 It is recommended that the core & windings only be removed from the
tank for visual inspection if PARTICULARLY necessary.
6.3.2 Following draining all oil from the tank, internal inspection should be
done via opened top cover or side inspection cover openings. DO NOT USE
NAKED FLAME OR LIGHT but SAFETY LAMP for internal inspection.
6.3.3 Before lifting the core & windings from the tank it is necessary to
disconnect the winding connections from terminal bushings inside the tank
and the earthing connection between the core and the tank. The core and
windings must be removed with great care, and when removed be stored
under the proper cover and in a dry place.
6.3.4. Windings should be examined to ensure that no sludge has been

deposited to block the oil ducts / opening passages.
6.3.5 OC Selector terminals shall be thoroughly cleaned and ensure no

welds / dents exist at tapping contacts. And that all the tapping leads are
properly insulated / supported without any loose sag. Also ensure smooth &
full operation of OCS.
6.3.6 Any loose nuts & bolts should be tightened and main clamping checked
for tightness.
6.3.7 After completion of examination, CHECK to ensure no foreign items

have been left inside the tank.
6.3.8 Alternative to this time consuming process, a regular DGA (Dissolved

Gas Analysis) of oil will give effective indication of any potential problems
beginning to occur. Also video camera technique can be used to carry out an
internal inspection quickly and with minimum problems
6.4 EXTERNAL OUTDOOR / INDOOR TERMINAL BUSHINGS
6.4.1 Outdoor Porcelain insulators and rain sheds should be cleaned at

regular intervals. Metallic scrubber can be used effectively to remove dirt /
stains.
29
6.4.2 During cleaning, the outdoor porcelain bushings should be examined
for oil leakage, cracks or other defects and defective ones should be replaced.
6.4.3 Arcing horns, if fitted, shall be checked for any arcing dents / welds and
correct gap setting. And any arcing horn with dents / welds are replaced or
rectified.
6.4.4 Indoor Porcelain Insulators, usually placed inside the cable box, do not
require cleaning under normal circumstances.
6.5 CABLE BOXES
6.5.1 In case of compound filled cable box, check regularly for leakage at
weatherproof plugging / sealing with bituminous compound, which shall be
free from any cracks.
6.5.2 In case of air-filled cable box (for Heat-Shrink / Push-On / other such
dry termination), though no maintenance is required, it is advisable to check
regularly for cleanliness, damages of bushings, tightness of termination, etc.
6.6 COOLING RADIATORS
6.6.1 Cooling Radiators should be checked for any oil leakages along all the
welded joints, gasket joints, plugs, etc.
6.6.2 Any bend, dents, etc., should be rectified as soon as possible.
6.7 CONSERVATOR
6.7.1 Conservators are arranged so that the lower part acts as a sump in
which any impurities entering the conservator will tend to collect. A valve is
fitted at the lowest point of the conservator for draining and sampling. When
sampling, care must be taken to run off any such sludge before taking oil
sample for testing.
6.7.2 The inside of the conservator should be cleaned and a removable end
is provided on each conservator for this purpose.
6.8 OIL GAUGES
6.8.1 Oil gauge should be kept clean and any damaged glasses should be
replaced immediately. The gauges are normally fitted with strengthened plate
glass which is unbreakable under normal service conditions.
6.9 DEHYDRATING BREATHER
6.9.1 The dehydrating breather should be regularly checked for colour of

desiccant. When the majority of gel becomes saturated, the same shall be
replaced or reactivated.
6.9.2 Oil in the oil seal, if used, should be maintained up to the level marked
on the cup.
30
6.9.3 The frequency of inspection depends upon local climate and operating
conditions. More frequent inspections are needed when the climate is humid
and when the transformer is subject to fluctuating load.
6.10 BUCHHOLZ RELAY
6.10.1 The relay should be routinely inspected and the operation of relay is
ensured by injecting air into the relay and check that floats are able to fall /
rise freely and that the mercury / magnetic switches are making / breaking the
contacts.
6.10.2 During service, if the relay is operated due to an accumulation of gas

and not due to fall of conservator oil level. Any internal faults can be identified
to a great extent by a chemical analysis of gas. Sometimes, on analyzing the
gas, it may be noticed that the gas collected is only air. This may be that the
oil is releasing any absorbed air during oil filtration or due to change in
temperature.
6.11 EXPLOSION VENT OR PRESSURE RELIEF DEVICE:
6.11.1 In an explosion vent, the diaphragm is fitted at the exposed end of the
vent, which should be inspected at frequent intervals and replaced if found
deteriorated / damaged. Failure to replace the defective diaphragm quickly
may allow the ingress of moisture, which will contaminate the oil. If the
diaphragm has broken due to an internal fault, a full inspection should be
made to determine the nature and cause of the fault BEFORE re-energising
the transformer.
6.11.2 In a spring loaded `blow-off & self or manual reset type Pressure Relief
Device, if the indicator, usually an oil-slick or a flag is operated, then an
inspection should be made to determine the cause of fault BEFORE re-
energising the transformer.
6.12 TEMPERATURE INDICATORS
6.12.1 The level of oil in the thermometer pockets should be checked and the
oil replenished, if required. The capillary tubing should be fastened down
again if it has become loose. Dial-glasses of temperature indicators should be
kept clean and, if broken, replaced. Temperature indicators if found to be
reading incorrectly should be re-calibrated with standard thermometer
immersed in hot oil bath.
6.13 SEALING GASKETS
6.13.1 Gaskets sometimes shrink during service. It is necessary to check the

tightness of all bolts fitted with gaskets. The bolts should be tightened evenly
around the joints to avoid uneven pressure. Damaged gaskets should be
replaced as soon as possible.
31
6.14 BOLT, NUTS & FASTENERS
6.14.1 All bolts, nuts, fasteners, etc., shall be thoroughly checked for proper
tightness and any deteriorated parts should be replaced.
6.15 PAINT-WORK
6.15.1 During storage and service, the paint-work should be inspected once a
year, especially at the welded seams / joints, and where necessary, painting
or retouching carried out. If the metal surface is exposed and becomes dirty,
rusty or greasy because of delay in repairing the paint-work, the surface must
be thoroughly cleaned with a wire-brush or similar abrasives, before
repainting to ensure a good bond between metal and paint. If paints
recommended by supplier are not available, any good quality alkyd resin-
based paint may be used.
6.16 VALVES
6.16.1 All valves should be checked for any leakage and for open / close
operation. Blind caps should always be kept fitted on them.
General Notes:
IT IS ESSENTIAL TO KEEP A RECORD OF OBSERVATIONS

MADE REGARDING OPERATING CONDITION, ANY TEST
PARAMETERS & TEST RESULTS OBTAINED.
IN CASE OF ANY ABNORMALITY OCCURRING DURING
SERVICE, ADVICE FROM THE SUPPLIERS SHOULD BE
OBTAINED, GIVING THEM NAME-PLATE PARTICULARS AND
COMPLETE DETAILS AS TO THE NATURE & THE EXTENT OF
OCCURRENCE.
32
6.17 MAINTENANCE SCHEDULE
Maintenance Schedule for the attention required under average condition is

given below;
Sl. Frequency of Items to be Inspection Notes Action required for

No. Inspection Inspected unsatisfactory conditions
01 Hourly / Daily Ambient Temp. For reference -
02 - do - Oil / Winding Check that temp rise is For any abnormal temp. rise
Temperature within the limit trip, investigate the cause.
03 - do - Load Voltage & Check against the rated For any abnormal tripping,
Current figures investigate the cause.
04 Weekly / as Dehydrating Check desiccant colour & Replace the desiccant or
convenient Breather oil seal make up the oil, as required.
05 - do - Oil level in Main Check the level against If low, investigate the oil leak
Tank oil temp. & top up with dry oil.
06 - do - Buchholz Relay Check gas collection Take suitable action to
prevent any potential fault.
07 - do - Gasket Joints & Check for tightness & oil Arrange for replacement /
Radiators leakage repair as required.
08 - do - Explosion Vent / Check for proper sealing / Rectify / Investigate the
Pr. Relief Device indicator damage / malfunction.
09 Quarterly / as Oil Check for dielectric Take suitable action to
convenient strength / sludge restore quality of oil.
10 - do - Cable Box / Check for tightness / dirt / Clean thoroughly, if needed,
Trmnl. Bushings damage take remedial measures.
11 - do - OCTC Check for smooth If required, replace oil / worn-
operation out parts.
12 Half Yearly / as Earthing Check tightness & Earth Take remedial action if earth
convenient Terminals Resistance resistance is high
13 - do - Accessories / Check operation & Clean the components, if
Auxiliary Circuits switching contacts. necessary, replace the item.
14 Yearly / as Buchholz relay / Mechanical inspection Check floats, contact
convenient Surge relay switches operation
15 - do - Insulation Check IR values If low investigate & take
Resistance action to restore insulation
16 - do - Fastening Bolts / Check for tightness Replace the defective
Screws / Clamps fasteners
17 - do - Paint-work Check for peelings / Repaint, as required.
rusting/ damage
18 Two Years / as Temperature Check operation & Clean the components, if
convenient indicator switching contacts. necessary, replace the item.
19 - do - Oil Gauge. Check operation & Clean the components, if
switching contacts. necessary, replace the item.
20 - do - Oil conservator Internal inspection Clean if necessary
21 3-5 Years / as Overall paint- Check for deterioration Consider full repaint to
convenient work original specification
22 - do - OCTC switches Check for arcing / Replace / Repair defective
welding / wearing components as necessary
23 - do - Core & Windings Check for tightness / Replace / Repair defective
cleanliness components as necessary
33
Section 4 Operations Procedures
Contents
4.0 General
4.1 Operating Instructions
4.2 Recommendations for Monitoring System Performance
4.0 General
It is important that personnel should be fully familiar with the operation of the various
devices that they are called upon to handle. Operation of switchgear during
maintenance is when most accidents and problems can occur. Make sure that all
staff are aware of what work is being carried out and that the switching operations
are in accordance with the Manufacturer's recommended instructions, and that work
is carried out when the equipment has been isolated and proved "dead" with a
reliable voltage indicating device.
All voltage indicating devices should be tested on a known "live" source immediately
before and after use. Using improvised voltage indicators should be discouraged.
Before work is carried out on or near parts which are normally live, or where danger
would arise to people working, it is essential that the apparatus is proved dead.
The operation of an external handle or lever of an isolator or circuit breaker should

not be assumed to have opened all or any of the contacts, as cases of mechanical
failure have been known to occur. In particular, this may happen where a handle is
operated against a mechanical interlock.
Tests should therefore be carried out to ensure that equipment is dead, that all the
contacts of the device are open and all the correct fuse carriers removed. These
should include tests between each phase and earth to cover the possibility of wrong
connection.
Precautions should be taken to ensure that control circuits to automatic equipment

are disconnected from the supply before work is commenced on such equipment.

It should not be assumed that the isolation of the main supply to the equipment
isolates auxiliary circuits, for example, contactor control circuit may be made "live"
from an alternative source.
In isolating auxiliary circuits to auxiliary equipment care should be taken that the
tripping supplies to other units are not affected.
All safety precautions and general recommended procedures relating to the

maintenance of switchgear are contained in the relevant British Standard Codes of
Practice.
Similar procedures should be adopted if there is a supply failure caused by a fault

either on the consumers' side or supply authorities' side of the installation. The
amount of isolation required will need to be adjusted to relate to the extent of the
failure or fault.
Switchgear associated with spare (unused) circuits should be locked off and for the
purpose of ensuring that the mechanism stays in good working order it should be
operated periodically by a competent person.
4.1 Operating Instructions
When undertaking maintenance work it should be noted that compliance with the
following should be ensured:
1. The IEE Wiring Regulations for Electrical Installations
2. The Electricity Supply Regulations
3. Health and Safety at Work Act 1974 and supplementary regulations
4. The Electricity at Work Regulations 1989 and amendments
5. Any special regulations issued by the Local Electricity Supply Authority
6. The Building Regulations
7. Local Authority requirements
8. Statutory instruments and regulations
9. Manufacturer / Supplier requirements
10. The Factories Act
11. Construction Regulations and associated statutory obligations
12. HSE Publications - "Avoiding Danger from Undergound Services"

If power failure occurs, first check to establish whether it is a Supply Authority failure
or a fuse blown on the customer's side of the installation. If it is established that it is
a Supply Authority failure, notify that Authority immediately.
Irrespective of the cause of supply failure, establish whether there will be any
damage to equipment or danger to staff if supply were to be suddenly restored. If
there is any chance of this, turn off switches until all equipment is isolated.
When the main supply is to be restored, warn all personnel who might be effected
and make sure the equipment to be re-energised will not cause danger before
switching on the isolators.
4.2 Recommendations for Monitoring the System Performance
It is recommended that all monitoring is recorded and kept in a book used

exclusively for this purpose.
Where practical the following data should be kept, however, experience of the particular installation may
dictate that different or additional information should be recorded.
1. Power consumption
Record Electricity Supply Authority meter readings every month.
2. Faults
Record details and dates of any faults occurring in the installation with
details of action taken and results.
3. Time Switches
Record settings of time switches and the date of any changes made.
4. Spares
Record dates and quantities of spares or replacement equipment

supplied.

Section 5 Maintenance Operations
Contents
5.0 General
5.1 Working Procedures
5.2 Switchgear and Distribution Boards
5.3 Electrical Checks
5.4 Marking Covers and Connections
5.5 Switches and Fuses
5.6 Control Circuit Fuses
5.7 Air Break Contactors
5.8 Recommended Maintenance
5.9 Main Distribution
5.0 General
These general notes are provided for the information and guidance of the
maintenance personnel. The notes are to be read in conjunction with any existing
procedures and site log books.
The maintenance of certain items of specialist systems such as fire alarms, door
access, CCTV, etc, because of the requirement for particular knowledge and
possibly the use of special equipment and methods, should only be undertaken by a
trained specialist. Some of these systems may also be subject to separate
maintenance contracts.
Maintenance instructions included within this section are basic exercises to ensure
efficient running of the equipment. However, reference should be made to the
manufacturers instructions (where available) for more specific detailed instructions
on dismantling, maintenance tasks, reassembly, etc.

After each maintenance operation on plant items, a brief note should be made on log
sheets indicating:
1. Type of Maintenance (eg weekly, monthly, yearly)

2. Any problem encountered
3. Materials used and re-ordering instructions
4. Time taken
5. Essential action necessary before the next routine maintenance inspection.
6. Details of any trends.
This information will help establish historic data from which accurate maintenance
forecasting can be made.
Frequency of Maintenance
The frequency of the maintenance will depend on a number of factors, the most
important being the conditions under which the equipment operates and the severity
of the duty it performs. For the purpose of this manual, the normal anticipated
periods have been assumed, but this does not preclude more frequent checks and /
or maintenance should it be found necessary from experience. For equipment that
operates continuously it may be necessary to co-ordinate routine maintenance with
the demands on the building usage. However, where there are regular periods when
equipment or systems are shut down, required maintenance tasks can be scheduled
to coincide with these periods.
The table below provides a summary of the recommended intervals between

maintenance inspections and actions as itemised in further detail within the actual
maintenance sheets included.
These routines would form the basis of any planned maintenance system that may
be incorporated by the building occupier.
In the event of any disparity between these recommendations and those indicated by
the manufacturer (now or at a later date) the manufacturer's information is to be
followed.
However, actual user experience and knowledge of trained maintenance personnel

will develop the long term maintenance requirements for this particular installation.

Suggested Periods of Maintenance
Each Each 3 6 1 2 5
Equipment Wk Mth Mths Mths Yr Yrs Yrs
1. Switchgear & Transformers * * *
2. Distribution Cables * * *
3. Distribution Boards * * *
4. General Lighting * * *
5. Emergency Lighting * * *
6. Small Power * * *
7. Fire Alarms * * *
8. Lightning Protection *
5.1 Working Procedures
BS 6423 deals with the maintenance of electrical switchgear and control gear of
voltages up to and including 650 volts, which includes detailed standards for
Maintenance, Operation and Safety, together with examples of certificates and
Permits to Work. In addition to this standard the Health and Safety Executive have
published a booklet reference HS (G) 3 entitled "Electrical Testing". It is strongly
recommended that these Standards are applied.
FAILURE TO COMPLY WITH RELEVANT HEALTH AND SAFETY AT WORK

REGULATIONS WILL MAKE EMPLOYERS AND EMPLOYEES LIABLE TO
PROSECUTION.
The area of highest risk is generally at control points, such as switchgear and
associated conductors which become exposing during any works carried out on
installation. These hazards are also present in varying degrees throughout any
installation, and they should be considered whenever working with potentially "Live"
equipment.
Should BS 5405 not be applied, the following elementary procedures may generally
be adopted to help ensure the safety of personnel and protect plant and equipment
from damage.
Whenever work is contemplated on any equipment, it should only start after a

"Permit to Work" control system is in place that ensures all necessary safety
precautions are identified, understood and put into effect. Access to switch room and
distribution equipment must be limited to Authorised Personnel, this includes all work
which necessitates the removal of covers or the exposure of any potentially "live"
equipment.
CAUTION NOTICES should be fitted, at the event of a fault, at appropriate

switchgear or distribution boards, defining the fault and warning of any possible
danger, all covers having been replaced after examination. Where possible, access
to the area should be restricted and all personnel affected by the isolation should be
warned, preferably in advance of the shut down.
In order to safely isolate any item of equipment the operative must first PROVE that
the item of equipment has been totally isolated from the main electrical supply and
from any emergency stand-by generators. This isolation must be locked off from any
third party with Danger Notices in place until the "Permitted" personnel are satisfied
that it is safe to re-energise the equipment. "Locking Off" could be confiscation of
fuses or padlocking of the isolator on the relevant distribution board. (To which
there are only keys held by the contractor carrying out the maintenance).
Test equipment used to prove isolation must be tested on a know live electrical
supply and BEFORE AND AFTER testing the isolated equipment.
Having proved beyond doubt that an item of equipment is "Dead" the maintenance
can now be carried out.
Whilst maintaining the installation the "Health and Safety at Work Act" and
"Electricity at Work Regulations" must be followed at all times.
SEC cannot accept responsibility for damage or accidents occurring whilst a third
party maintains this electrical installation.
Before re-energising the electrical supply all barriers, lids and covers must be
replaced. Caution notices and padlocks, etc, can now be removed and the supply
re-energised.
The IEE Wiring Regulations (BS 7671) requires that earth continuity must be
maintained for all equipment and metalwork that presents a possible electrical
hazard. This forms a zone of equipotential earthing which is at the same potential
as
the earth provided by the Supply Authority. Should it become necessary to
disconnect this earth, the circuit or installation which this is apart must also be
adequately isolated. The earth continuity should also be checked on a regular basis
to ensure that this conductor is complete.
Cabinets for electrical equipment should be designed and maintained to exclude

water and condensation. Where the latter cannot be avoided, anti-condensation
preparations, ie "Silica Gel" etc, should be used.
Wherever possible, non conductive tools and equipment should be used to avoid
"shorting across" which will prevent dangers to personnel and equipment.

5.2 Switchgear and Distribution Boards
For equipment to operate satisfactorily, it is essential that it should be kept clean.

Before removing covers and opening doors, loose dirt and dust resting on top of
enclosures should be removed with a brush. Ensure correct PPE is used.
1. When air is used for cleaning, a suction type device with a dust
receptacle should preferably be employed. If it is necessary to use
compressed air it is preferable to employ a portable type blower.
2. "Cotton Waste" should be used for cleaning. If clothes are used they
should be chemically clean and free from loose fibres.
3. When solvents are used for cleaning or degreasing, they should be of

a non-flammable and non-toxic nature whenever possible, and at all
times precautions against fire should be observed.
After maintenance work, all covers and doors including those of instruments and
relays should be securely placed so as to exclude dust.
5.3 Electrical Checks
Regular checks of the tightness of all terminations and connections are required on
the switchgear including those on the main bus-bar systems. Check the
instrumentation and controls including voltmeter switches for correct operation and
replace fuses and switches as necessary.
5.4 Marking of Covers and Connections
All covers, cables and shields etc, should be marked carefully before removal to
ensure correct replacement.
If connections are disturbed or temporary connections made for testing purposes,

they should be clearly marked to facilitate re-connection and the permanent
connection must be restored and the temporary connections removed before the unit
is returned to service.
After maintenance work, bolts, screws and locking devices of all current carrying /
earth connections should be securely tightened.
Connections which have not been disturbed should be checked for soundness. It is
not sufficient for nuts and bolts to be assumed to be tight.

5.5 Switches and Fuses
Circuit wiring and terminal connections must be checked for signs of overheating,
replace parts where there is the slightest doubt that this has occurred. Where
cartridge fuses are used, replacements should be of the same patterns as the
original and in no circumstances should attempts be made to rewire a non-
re-wireable fuse.
Where a locking device hold the fuse in position, it should be remembered that the
fuse links incorrectly chosen, or badly fitted, may contribute to overheating. To
avoid knife contacts from sticking, they should be lightly smeared with petroleum jelly
or other such suitable lubricant.
5.6 Control Circuit Fuses
The reliability of equipment can be seriously impaired by control faults and it is

therefore most important to locate and correct immediately, any fault which causes
the operation of any control circuit fuse and to report the occurrence.
Every fuse link should be tested for continuity each time a routine inspection is
carried out, where this is not an inevitable part of the final running test. Clear
labelling of fuses in agreement with connection diagrams is also desirable. Such
labelling should also indicate the fuse rating.
5.7 Air Break Contactors
The correct treatment of contactors depends upon the materials of which they are
made as well as upon the duty of the equipment. Contacts should never be
lubricated with either grease or oil. Silver or silver plated contacts seldom require
cleaning in- spite of a frequently discoloured appearance.
5.8 Recommended Maintenance
Note: In the interest of safety it is strongly recommended that maintenance work be

carried out ONLY when standing upon a rubber safety mat, which should be
permanently located in front of the main switch panel.
Weekly Checks

1. Make general inspection of the electrical switch room and main

switchboards to ensure that the equipment is clean and the area
is free from obstruction.
2. Examine the main switchboard for any signs of overheating.
3. Check for any electrical discharge noises indicating loose

components.
4. Check to ensure that special tools and isolating equipment are

serviceable and in their proper storage position.
5. Remove all external dirt from the switchboard using proper

materials.
6. Examine and check all earth connections.
7. Log electrical consumption.
8. Check that all indicator lamps are functioning correctly for the
switches in operation and replace faulty lamps.
Monthly Checks
1. Ring Main Unit
a. General Inspection
b. Check oil level reading and any signs of leakage.
2. LV Circuit Breaker
a. Check enclosure for water penetration

b. Check MCCB connections for signs of overheating
c. Operate (trip / close) MCCB on no-load
3. Earthing
a. Inspect / check connections

b. Test earth electrode resistance
Annual Checks
1. Clean all insulating surfaces
2. Clean and inspect arc shields / arc shrouds, renewing where

there is any evidence of damage

3. Inspect fixed and moving contacts, examine for any signs of

burning, arching or overheating
4. Clean switch contacts as necessary
5. Renew switch contacts where necessary
6. Lightly lubricate all moving parts
7. Check switches for correct operation
5 Yearly Checks
1. An inspection and test must be carried out by a competent

electrician, which will include the switchgear and distribution
boards, to ensure that they meet the requirements of the IEE
Wiring Regulations (BS 7671).
5.9 Main Distribution
This procedure will incorporate the entire length of the main distribution cables,
establishing the mechanical strength of the cable support.
Three Monthly Checks
1. Check security of cable trays, trunking, etc.
Six Monthly
1. General inspection for damage and sagging
2. Temperature check for overheating. It must be noted that XLPE

cables, the insulation is designed to be able to operate with
safety at higher temperatures.
3 Yearly Check
1. Carry out insulation, earth loop impedance and earth continuity

test on the whole installation.

Note
Tests need not be carried out at one time. It is quite acceptable to split
the installation to smaller sections and carryout tests at more frequent
intervals, provided that all parts of the installation receive a test every
three years.

Section 6 Emergency Procedures

Contents
6.0 Emergency Procedure - Mains Supply Failure
6.1 Emergency Procedure - First Aid
6.0 Emergency Procedure - Main Supply Failure
In the event of a main electrical supply failure Southern Electric plc can be contacted
on the following telephone numbers:
General Enquiries 08457 718191
Emergencies (Loss of Supply - 24 hour) 08000 727282
6.1 Emergency Procedure First Aid
Treatment of Electric Shock (as recommended, September 2002)
IMMEDIATE SPEEDY ACTION IS NECESSARY.
Remove from Danger (Electricity, Water, Gas, Fumes, etc.)
Switch off current immediately or send someone to do so. Do not attempt to remove
a person from contact with high voltage unless suitable articles insulated for the
system voltage are used for this purpose. When attempting to free a person from
contact with low voltage use rubber gloves, boots or mat or insulated stick. If these
are not available use a rope, cap or coat to drag the person free. Whatever is used
should be dry and non conducting.
After Release

DO NOT WASTE TIME. If possible, lay casualty on firm, dry surface and check for
breathing and pulse. If there is a pulse but no breathing commence MOUTH TO
MOUTH RESUSCITATION.
Mouth to Mouth Resuscitation
1. Place the fingertips of one hand under the casualtys chin and
place the palm of your other hand on the casualtys forehead.
Gently tilt the head backwards and raise the chin to open the
airway. If head or neck injuries suspected tilt head back very
carefully and only far enough to open the airway.
2. Remove any blockages from the mouth. Look, listen, and feel for
breath for up to 10 seconds only. If casualty is not breathing
commence Mouth to Mouth resuscitation.
3. Keeping the airway open, pinch the casualty's nose shut with your
thumb and forefinger. Take a breath and seal your lips around the
casualty's lips, breathe steadily into the casualty's mouth for about
two seconds watching the chest rise. Take your mouth away and
allow the chest to fall. Repeat once.
4. If the chest fails to rise during inflation, check that the jaw is lifted,
the head tilted back and the mouth and throat are clear of
obstructions.
5. After two rescue breaths have been given check for breathing for
upto 10 seconds. If there is circulation but the casualty is still not
breathing continue with Mouth to Mouth resuscitation for another 10
rescue breaths. Check for signs of breathing for upto 10 seconds,
then commence another 10 rescue breaths. Continue, checking for
circulation after every 10 breaths until the casualty starts breathing
again or medical help arrives. If breathing starts, turn the casualty
into the RECOVERY POSITION (see Note).
6. If you must leave the casualty to dial 999, give 10 breaths first,
return quickly and continue, checking for circulation after every 10
breaths.
7. If there is no circulation SEND FOR AN AMBULANCE and

commence CARDIO PULMONARY RESUSCITATION immediately.
In the rare situation where a First Aider may be alone with a
casualty, he / she must assess the situation and decide whether to
proceed immediately with resuscitation or to dial 999 first, taking
into consideration the distance between him / her and the nearest
telephone, and the time it will take to summon help.

Cardio Pulmonary Resuscitation
1. Measure two finger widths up from the bottom of the breastbone.

Place the heel of one hand on the chest next to the two fingers.
Move the fingers away and put the heel of the other hand on top
of the first hand. Interlock the fingers of both hands.
2. From the kneeling position by the side of the casualty, rock

forward with arms held straight (keeping the fingers off the
chest) pushing down on the chestbone with the heel of your
hands. Release pressure. Compression should be regular and
smooth not jabbing or jerking.
3. Continue until 15 heart compressions have been given (aim for a rate of 100
compressions per minute). Cease CPR and give two rescue breaths (see Mouth to
Mouth resuscitation). Repeat, giving two rescue breaths after every 15
compressions.
4. If the casualty shows sings of improvement, recheck circulation.

If circulation is confirmed but the casualty is not breathing, stop
compressions and continue with mouth to mouth resuscitation.
5. Check the circulation after every 10 inflations and be prepared

to restart chest compressions if circulation is absent.
6. If the casualty starts to breath unaided, place him / her into the
RECOVERY POSITION. Constantly monitor airway breathing
and circulation.
NOTE: If spinal injury is suspected at least two people are needed to

place casualty into recovery position ensuring that:
1. The head and neck are steadied and supported throughout by placing your
hands over the casualty ears, be prepared to maintain this support until the medical
help arrives do not pull at the neck.
2. Casualty's legs are straightened, near arm out, elbow bent, palm uppermost,
at right angles to body.
3. As helper proceeds to position casualty ready for placing in the

recovery position. The neutral position of the head and neck must
be maintained.
4. Once casualty is fully turned onto his / her side, maintain support
until medical help arrives.
5. If one of you has to go to summon aid send helper, keep casualty

steady with rolled blankets, coats, etc., placed alongside.

Other Injuries
Control of Bleeding
Apply firm pressure directly to the wound and where possible, raise injured
part.
Cover with clean dressings and bandage firmly in place.
If bleeding continues add further dressings on top of the first and increase the
pressure by bandaging firmly in place.
Treatment of Burns
Burns should be cooled with cold, running water if available.
Then cover with a clean, preferably sterile, dressing and bandaged lightly in
position.
If transfer to hospital is desirable, dial 999 and request the local ambulance
service.
First Aid Appliances
The First Aid equipment provided shall be used only for the purpose intended.
The Health and Safety Regulations 1981
SI 1981 917 place a general duty on employers to make adequate first aid provision
for their employees if they are injured or become ill at work. Employers must inform
their employees of the provisions made for them.
A revised Approved Code and guidance notes are published together in the Health
and Safety Executive booklet "First Aid at Work" HS(R)11.

Section 7 Plant Malfunction

Contents
7.0 Introduction
7.0 Introduction
This section covers the handling of plant malfunction. Plant in the context of
electrical installations covers, specialist systems installed under the electrical
contract.
These systems are either installed in their entirety by a specialist supplier/installer or

installed by SEC and commissioned by a specialist supplier.
Malfunctions of basic electrical equipment such as standard switchgear, wiring

accessories and lighting, can be handled by trained, competent electrical
maintenance personnel. However malfunctions of specialist systems should be
handled by the specialist manufacturer/installer or their nominated agent.
There are no specialist systems within this contract.
Project Ref:162031 Operations & Maintenance Manual Section 7 Page 1

Section 8 Recommended Spares

Contents
8.1 Introduction
8.1 Introduction
All electrical installations are subject to wear and tear, and certain components such
as lamps have a limited operational life. In addition certain items of equipment may
be subjected to mechanical damage.
Replacement items such as lamps are readily available at electrical wholesalers,

while more specialist equipment such as specialist smoke detector heads are not.
These specialist items often have to be purchased directly from the manufacturer
and may be subject to longer lead times.
In order to minimise the delay in bringing the installation back to normal state, it is
recommended that the following spares are held. It is also prudent to record and
monitor the usage of spares such that reordering can be take place in good time.

Section 9 Design Data, Test & Commissioning
Contents
9.1 Test & Commissioning Certificates
9.1 Test & Commissioning Certificates

The following test and commissioning certificates are included:-
System Provider Ref.

High Voltage Test Record SEC J08-4992-J/D
Transformer Report SEC T1
Transformer Report SEC T2
Ring Main Unit Report SEC RMU 1
Secondary Injection test 1 SEC RMU 1
Ring Main Unit Report SEC RMU 2
Secondary Injection test 2 SEC RMU 2
RMU 1 Test Cert. Richard Wilson(Dencol)Ltd. 100494496
RMU 2 Test Cert. Richard Wilson(Dencol)Ltd. 100394071

High Voltage Test Record
Site Name: B&WHW KNAPP MILL CHRISTCHURCH
Location On Site: INTAKE S/STN
Date Of Test: 29.10.08 Test Equipment ID Nos
o
Sanction For Test N J08-4992-J/D Test Carried Out By: G HANKINS
Reason Test Before First Commissioning Test Megger

Carried Out After Alteration Or Repair Voltage AC Test Set
Source DC Test Set
Tick Appropriate Boxes
LINE DIAGRAM OF EQUIPMENT INCLUDED IN TEST
Intake s/s Treated Water P/H s/s Fawley P/H s/s
T1 T2
Open
Test
injected
here
Test Results
Equipment Core Or Test Period Of Leakage Insulation Remarks
Phase Under Voltage Test (Mins) Current Resistance
Test (kV) (A ) (M)
Cable, jointing R/Y-B/E 18 5 1.80 <999 Good Test
and
switchgear
Ditto Y/B-R/E 18 5 1.10 <999 Good Test
Transformer 1 R/Y/B-E 18 1 3.80 <999 Good Test
Transformer 2 R/Y/B-E 18 1 4.20 <999 Good Test
OVER VOLTAGE TEST ON HIGH VOLTAGE EQUIPMENT CARRIED OUT IN ACCORDANCE WITH SEC Ltd OPERATIONAL PROCEDURES.
General Comments (If Required):
Signature Of Test Eng: G W Hankins Date: 30.10.08
XHV 40 COM
Transformer Commissioning Report
Sub Station Name: TREATED WATER PUMP HOUSE
Transformer Name: T1 SEC Job Number
Transformer Type Oil Test Equipment ID No
Manufacturer: PDT
kVA Rating: 1000
Serial Number: 1298161 Commissioned By: G HANKINS
Vector Group Dy11 Engineer In Charge: G HANKINS
Voltage Ratio 11000/433 Date Commissioned: 29.10.08
Item Tick Comments

General Inspection
Circuit I.D. Labels fitted
Statutory Labels fitted B&WHW building
Oil Level checked & Topped Up As Necessary
Silica Gel Breather fitted as Necessary
Air breather free to ventilate
Patch painting carried out where required Not Required
Cooling Fins opened and checked for damage
Transformer secured in position to adequate base
Access suitably restricted to any exposed parts
Off Load Tap Changer
Oil Leaks
Correct TAP setting applied & padlocked Tap 1
Earth Connections
Main N-E link fitted and continuity proved B&WHW at LV switchboard
Position of Main N-E link B&WHW at LV switchboard
Conductor connection of general earthing Steelwork earth
HV Cable Box
HV Conductor Connection No cable box tank mounted switch
Number size and type of HV conductors per phase
Condition Of Bushings / Oil Leaks
Earth connection to main tank
LV Cable Box
LV Conductor Connection
Number size and type of LV conductors per phase 4 x 500mm copper pvc
Number size and type of LV conductors neutral 2 x 500mm copper pvc
HV & LV Protection settings
Correct protection applied to HV controlling device
Correct protection applied to LV controlling device N/A B&WHW contractor
Main LV isolator locked open SL&CN applied B&WHW contractor lock
XHV059 COM Page 1 of 2

Conservator Tank N/A
Draw Off Tap
Check Pipework & Buchholz For Oil Leaks
Fit or fill Silica Gel Breather As Necessary
Temperature Sensor Indication
Low Oil Alarm Level On Buchholz Oil Level =
Low Oil Trip Level On Buchholz Oil Level =
Surge On Buchholz Operates Trip Minimum Pressure =
Ensure Buchholz free of air pockets
Pressure Vent Diaphragm trip operation
Pressure Tests
HV winding to earth 3.8 A Remarks
LV winding to earth N/A G Remarks
HV to LV winding and earth N/A A/G Remarks
Transformer cable test record See separate sheet
Continuity Tests N/A Factory test
Transformer flick test carried out
HV winding continuity tests carried out R-Y Y-B R-B
LV winding continuity tests carried out R-N Y-N B-N
Post Energisation checks
Final Tap selected position Tap 1
Phase to phase off load voltage recorded R-Y 426V Y-B 426 V R-B 426 V
Phase to neutral off load voltage recorded R-N 242 V Y-N 242 V B-N 242 V
Phase to neutral off load voltage recorded R-N V Y-N V B-N V
Phase to earth off load voltage recorded R-E V Y-E V B-E V
Earth loop impedance measured value Position taken
LV Phase rotation Standard Position taken LV ACB connections
Phasing proved between interconnecting systems
Any Additional Items Checked
Details of any special precautions, deviations or omissions:-
Report Examined By: G Hankins Date: 30.10.08

Transformer Commissioning Report
Sub Station Name: TREATED WATER PUMP HOUSE
Transformer Name: T2 SEC Job Number
Transformer Type Oil Test Equipment ID No
Manufacturer: PDT
kVA Rating: 1000
Serial Number: 1298160 Commissioned By: G HANKINS
Vector Group Dy11 Engineer In Charge: G HANKINS
Voltage Ratio 11000/433 Date Commissioned: 29.10.08
Item Tick Comments

General Inspection
Circuit I.D. Labels fitted
Statutory Labels fitted B&WHW building
Oil Level checked & Topped Up As Necessary
Silica Gel Breather fitted as Necessary
Air breather free to ventilate
Patch painting carried out where required Not Required
Cooling Fins opened and checked for damage
Transformer secured in position to adequate base
Access suitably restricted to any exposed parts
Off Load Tap Changer
Oil Leaks
Correct TAP setting applied & padlocked Tap 1
Earth Connections
Main N-E link fitted and continuity proved B&WHW at LV switchboard
Position of Main N-E link B&WHW at LV switchboard
Conductor connection of general earthing Steelwork earth
HV Cable Box
HV Conductor Connection No cable box tank mounted switch
Number size and type of HV conductors per phase
LV Cable Box
LV Conductor Connection
Number size and type of LV conductors per phase 4 x 500mm copper pvc
Number size and type of LV conductors neutral 2 x 500mm copper pvc
HV & LV Protection settings
Correct protection applied to HV controlling device
Correct protection applied to LV controlling device N/A B&WHW contractor
Main LV isolator locked open SL&CN applied B&WHW contractor lock

Draw Off Tap
Check Pipework & Buchholz For Oil Leaks
Fit or fill Silica Gel Breather As Necessary
Temperature Sensor Indication
Low Oil Alarm Level On Buchholz Oil Level =
Low Oil Trip Level On Buchholz Oil Level =
Surge On Buchholz Operates Trip Minimum Pressure =
Ensure Buchholz free of air pockets
Pressure Vent Diaphragm trip operation
Pressure Tests
HV winding to earth 3.8 A Remarks
LV winding to earth N/A G Remarks
HV to LV winding and earth N/A A/G Remarks
Transformer cable test record See separate sheet
Continuity Tests N/A Factory test
Transformer flick test carried out
HV winding continuity tests carried out R-Y Y-B R-B
LV winding continuity tests carried out R-N Y-N B-N
Post Energisation checks
Final Tap selected position Tap 1
Phase to phase off load voltage recorded R-Y 426V Y-B 426 V R-B 426 V
Phase to neutral off load voltage recorded R-N 242 V Y-N 242 V B-N 242 V
Phase to neutral off load voltage recorded R-N V Y-N V B-N V
Phase to earth off load voltage recorded R-E V Y-E V B-E V
Earth loop impedance measured value Position taken
LV Phase rotation Standard Position taken LV ACB connections
Phasing proved between interconnecting systems
Any Additional Items Checked
Details of any special precautions, deviations or omissions:-
Report Examined By: G Hankins Date: 30.10.08

High Voltage Switchgear
Commissioning Report
Sub Station Name: TREATED WATER PUMP Test Equipment ID No
HOUSE
Equipment Name: RMU 1
Serial Number: 100494496 Date Of Test: 28 OCT. 2008
Test Witnessed By: Test Carried Out By: J PIDGEON / GH
1. General Data:
Manufacturer: SCHNEIDER Short Circuit Capacity: 21KA (3sec)
Mnf Type / Ref: RN2C-T1/21 Normal Rating: 630A
Equip Type (RMU,Sw,Etc) RMU Protection System: VIP300
Oil / Vac / SF6: SF6 Fuse / TLF Rating: N/A
System Voltage: 11000 Trip Coil Rating: 2A
2. General Checks:
(Tick)
(a) All setting dimensions of Unit and mechanical alignment to manufacturers recommendations.
(b) SF6 pressure
(c) All insulators are undamaged and clean.
(d) All chambers are clean and free of foreign matter.
(e) All small wiring within chambers is adequately protected and screened.
(f) Earth continuity of Unit to substation earth grid proved.
(g) Tightness of all electrical connections confirmed.
(h) Busbar joints properly made off and insulated. N/A
(i) All rating and identification plates, etc. are fitted and are satisfactory.
(j) Contacts and relational settings of auxiliary switches are correct. Factory
(k) Operation of Open / Closed / Earth indication confirmed.
(i) Breather and vents checked (where fitted). N/A
(m) Ancillary apparatus (e.g. operating handles, earthing devices, test devices, etc.) checked.
(n) Operational and safety lock facilities operate correctly.
(o) All operational locks have been fitted and locked. B&WHW
(p) All required name labels and warning notices have been fitted and are satisfactory.
3. Interlock Checks:
(Tick)
(a) Move selector to Normal position and Close main switch to On.
(b) Prove HV Fuse Cover will not open (if applicable). N/A
(c) Prove test facility will not open.
(d) Prove selector will not move to Earth position.
(e) Prove earth switch will not Close to Earth.
(f) Open main switch to Off position.
(g) Prove HV Fuse Cover will open (if applicable). N/A
(h) Prove test facility will not open.
(i) Prove earth switch will not Close to Earth.
(j) Move selector to Earth position.
(k) Prove HV Fuse Cover will open (if applicable). N/A
(i) Prove test facility will not open.
(m) Prove main switch will not Close to On.
(n) Close earth switch to Earth.
XHV 41 COM Page 1 of 2

3. Interlock Checks (Cont):
(Tick)
(o) Prove HV Fuse Cover will open (if applicable). N/A

(p) Prove test facility will open.
(q) Prove selector will not move to Normal position.
(r) Prove earth switch will open to Off with test device inserted / cover open. N/A
(s) Prove main switch will not close to On with test device inserted / cover open.
(t) Repeat checks for each switch of multi switch units.
4. Electrical Tests: (See separate result sheets)

(Tick)
(a) Primary Insulation (Insulation resistance between phases and to earth with breaker closed).
(b) V.T. Ratio, Polarity, connections and integrity proved. N/A
(c) C.T. Ratio, Polarity, connections and integrity proved.
(d) Small wiring insulation proved.
(e) Protection system proved.
(f) Voltage withstand proved.
(g) Voltage withstand across open switches proved.
(h) Circuit Breaker Timing Test
(i) Continuity Resistance Test Of Main Conductors:
* Test to be across all new joint with CB racked in and closed. W ere applicable, a test from the V.T. to busbar should also be made
Signature Of Witness: Date:

High Voltage Switchgear
Commissioning Report
Sub Station Name: TREATED WATER PUMP Test Equipment ID No
HOUSE
Equipment Name: RMU 2
Serial Number: 100394071 Date Of Test: 28 OCT. 2008
Test Witnessed By: Test Carried Out By: J PIDGEON / GH
1. General Data:
Manufacturer: SCHNEIDER Short Circuit Capacity: 21KA (3sec)
Mnf Type / Ref: RN2C-T1/21 Normal Rating: 630A
Equip Type (RMU,Sw,Etc) RMU Protection System: VIP300
Oil / Vac / SF6: SF6 Fuse / TLF Rating: N/A
System Voltage: 11000 Trip Coil Rating: 2A
2. General Checks:
(Tick)
(a) All setting dimensions of Unit and mechanical alignment to manufacturers recommendations.
(b) SF6 pressure
(c) All insulators are undamaged and clean.
(d) All chambers are clean and free of foreign matter.
(e) All small wiring within chambers is adequately protected and screened.
(f) Earth continuity of Unit to substation earth grid proved.
(g) Tightness of all electrical connections confirmed.
(h) Busbar joints properly made off and insulated. N/A
(i) All rating and identification plates, etc. are fitted and are satisfactory.
(j) Contacts and relational settings of auxiliary switches are correct. Factory
(k) Operation of Open / Closed / Earth indication confirmed.
(i) Breather and vents checked (where fitted). N/A
(m) Ancillary apparatus (e.g. operating handles, earthing devices, test devices, etc.) checked.
(n) Operational and safety lock facilities operate correctly.
(o) All operational locks have been fitted and locked. B&WHW
(p) All required name labels and warning notices have been fitted and are satisfactory.
3. Interlock Checks:
(Tick)
(a) Move selector to Normal position and Close main switch to On.
(b) Prove HV Fuse Cover will not open (if applicable). N/A
(c) Prove test facility will not open.
(d) Prove selector will not move to Earth position.
(e) Prove earth switch will not Close to Earth.
(f) Open main switch to Off position.
(g) Prove HV Fuse Cover will open (if applicable). N/A
(h) Prove test facility will not open.
(i) Prove earth switch will not Close to Earth.
(j) Move selector to Earth position.
(k) Prove HV Fuse Cover will open (if applicable). N/A
(i) Prove test facility will not open.
(m) Prove main switch will not Close to On.
(n) Close earth switch to Earth.

3. Interlock Checks (Cont):
(Tick)
(o) Prove HV Fuse Cover will open (if applicable). N/A

(p) Prove test facility will open.
(q) Prove selector will not move to Normal position.
(r) Prove earth switch will open to Off with test device inserted / cover open. N/A
(s) Prove main switch will not close to On with test device inserted / cover open.
(t) Repeat checks for each switch of multi switch units.
4. Electrical Tests: (See separate result sheets)

(Tick)
(a) Primary Insulation (Insulation resistance between phases and to earth with breaker closed).
(b) V.T. Ratio, Polarity, connections and integrity proved. N/A
(c) C.T. Ratio, Polarity, connections and integrity proved.
(d) Small wiring insulation proved.
(e) Protection system proved.
(f) Voltage withstand proved.
(g) Voltage withstand across open switches proved.
(h) Circuit Breaker Timing Test
(i) Continuity Resistance Test Of Main Conductors:
* Test to be across all new joint with CB racked in and closed. W ere applicable, a test from the V.T. to busbar should also be made
Signature Of Witness: Date:

RWD TC01 REVA 16/9/02
RICHARD WILSON (DENCOL) LTD.

HV SWITCHGEAR TEST CERTIFICATE (RMU)
CUSTOMER S.E.C. CONTRACT NO 1301 B

MANUFACTURER MERLIN GERIN SERIAL NO 100394071
TYPE RN2C - T2/21 FREQUENCY 50 Hz
SERVICE VOLTAGE 13800 V INSULATION MEDIUM SF6
RUPTURING CAPACITY 21 KA CURRENT RATING 630/200 A
SWITCHGEAR INFORMATION
OPERATION TYPE HAND D ELECTRIC
AUXILARY VOLTAGES 20-48 V DC , 110-250 V AC/DC
RELAYS VIP 300
CURRENT TRANSFORMER RATIOS PROTECTION 200/1 A
SWITCHGEAR TEST DOCUMENTS ENCLOSED

HVTS 01 DOCUMENT PRIMARY
RESISTANCE TEST D
HVTS 02 DOCUMENT INSULATION TEST D
HVTS 03 PRIMARY INJECTION TEST D
HVTS 04 MISCELLANEOUS TEST D
TESTED BY S.SMART DATE 02/06/2008

DOCUMENT HVTS01
HV PRIMARY RESISTANCE TEST REV 1
(DUCTOR) 20/07/2005
DATE 02/06/2008 CONTRACT NO 1301 B

SERIAL NO 100394071
CIRCUIT L.H. FEEDER SWITCH TO R.H. FEEDER SWITCH
RESULTS
RED PHASE 96
YELLOW PHASE 101
BLUE PHASE 98
CIRCUIT L.H. FEEDER SWITCH TO TRANSFORMER SWITCH
RESULTS
RED PHASE 94
YELLOW PHASE 85
BLUE PHASE 105
CIRCUIT R.H. FEEDER SWITCH TO TRANSFORMER SWITCH
RESULTS
RED PHASE 104

YELLOW PHASE 89
BLUE PHASE 90
TEST EQUIPMENT
DUCTOR RW27
COMMENTS
TEST ENGINEER S.SMART

DOCUMENT HVTS01
HV PRIMARY RESISTANCE TEST REV 1
(DUCTOR) 20/07/2005
DATE 02/06/2008 CONTRACT NO 1301 B

SERIAL NO 100394071
CIRCUIT L.H. FEEDER SWITCH TO EARTH
RESULTS
RED PHASE 119

YELLOW PHASE 121
BLUE PHASE 130
CIRCUIT R.H. FEEDER SWITCH TO EARTH
RESULTS
RED PHASE 91
YELLOW PHASE 99
BLUE PHASE 108
CIRCUIT TRANSFORMER SWITCH TO EARTH
RESULTS
RED PHASE 199

YELLOW PHASE 210
BLUE PHASE 229
TEST EQUIPMENT
DUCTOR RW27
COMMENTS
TEST ENGINEER S.SMART

DOCUMENT HVTS02
HV SWITCHGEAR INSULATION TEST SHEET
REV1 14/07/2005
DATE 02/06/2008 CONTRACT NO 1301 B SERIAL NO 100394071
ALL SWITCHES IN ''ON'' POSITION

R-Y,B,E Y-B,R,E B-R,Y,E
PRE-MEGGER
50000 M 50000 M 50000 M
2500v DC
PRESSURE TEST
1.13 mA 1.02 mA 1.12 mA
24000 V AC FOR 1 MIN
POST-MEGGER
50000 M 50000 M 50000 M
2500v DC
TRANSFORMER SWITCH ''ON' TRANSFORMER SWITCH ''OFF'

FEEDER SWITCHES ''OFF'' FEEDER SWITCHES ''ON''
R,Y,B.- r,y,b R,Y,B.- r,y,b
PRE-MEGGER PRE-MEGGER
50000 M 50000 M
2500v DC 2500v DC
PRESSURE TEST PRESSURE TEST

1.86 mA 1.89 mA
24000 V AC FOR 1 MIN 24000 V AC FOR 1 MIN
POST-MEGGER POST-MEGGER
50000 M 50000 M
2500v DC 2500v DC
TEST EQUIPMENT
MEGGER RW17 TEST ENGINEER
HV TEST SET RW13 S.SMART
DOCUMEN
HV SWITCHGEAR PRIMARY INJECTION TEST SHEET
REV1
DATE 02/06/2008 CONTRACT NO 1301 B SERIAL NO 100394071
CT MANUFACTURER N POWER HIGH RATIO LOW RATIO
RATIO 200/1 A PRIMARY SEC PRIMARY SEC SPILLS HIGH RATIO LOW RATIO FLICK TEST
R CT SER NO
CT TYPE RING
E1259N737/17942
200 A 0.99 A A A RY 2.32 mA mA R D
Y CT SER NO
CT CLASS PX
E1259N737/17943
200 A 1.00 A A A YB 0.19 mA mA Y D
B CT SER NO
CT VA
E1259N737/17944
200 A 0.99 A A A RB 2.20 mA mA B D
CT MANUFACTURER HIGH RATIO LOW RATIO
RATIO A PRIMARY SEC PRIMARY SEC SPILLS HIGH RATIO LOW RATIO FLICK TEST
R CT SER NO
CT TYPE A A A A RY mA mA R
Y CT SER NO
CT CLASS A A A A YB mA mA Y
B CT SER NO
CT VA A A A A RB mA mA B
PRIMARY INJECTION
RWD 01
TEST SET
FLICK TEST SET RWD 04 TEST ENGINEER
AMMETERS RW33 , RW50 S.SMART

NT HVTS03
12/07/2005
DOCUMENT
MISCELLANEOUS TEST SHEET NO REV REVISION DATE
HVTS 04 A 16/09/2002
EQUIPMENT DESCRIPTION DATE CONTRACT NO SERIAL NO. 100394071

RN2C - T2/21 02/06/2008 1301 B
CUSTOMER HALSALL
VIP 300 SECONDARY INJECTION

SETTINGS L1 L2 L3 E/F
20 A TAP (100mA), Io 20 A , Ios 12 A , CURVE SI , TMS 1.0
PICK UP 118 m A 118 m A 117 m A 71 m A
INJECT 0.2 A (X2) Io , 0.12 A (X2) Ios 10.20 s 10.11 s 10.22 s 10.20 s
INJECT 0.6 A (X6) Io , 0.36 A (X10) Ios 4.13 s 4.12 s 4.13 s 4.13 s
HIGH SET 0.4 A ( X4 ) Io , 0.24 A (X4) Ios 380 m A 380 m A 380 m A 230 m A
40 A TAP (200mA), Io 40 A , Ios 24 A CURVE SI , TMS 1.0

PICK UP 236 m A 236 m A 236 m A 141 m A
INJECT 0.4 A (X 2) Io , 0.24 A (X2) Ios 10.03 s 10.09 s 10.01 s 10.01 s
INJECT 1.2 A (X 6) Io , 0.72 A (X6) Ios 4.16 s 4.18 s 4.16 s 4.13 s
HIGH SET 0.8 A ( X4 ) Io , 0.48 (X4) Ios 770 m A 760 m A 767 m A 460 m A
TEST ENGINEER
S.SMART
DOCUMENT
MISCELLANEOUS TEST SHEET NO REV REVISION DATE
HVTS 04 A 16/09/2002
EQUIPMENT DESCRIPTION DATE CONTRACT NO SERIAL NO. 100394071

RN2C - T2/21 02/06/2008 1301 B
CUSTOMER HALSALL
VIP 300 PRIMARY TRIPPING
SETTINGS R-Y Y-B B-R E/F
20 A TAP , Io 20 A 20 A TAP , Io 12 A
CURVE SI , TMS 1.0 CURVE SI , TMS 1.0
INJECT 40 A (X 2) 10.17 s 10.03 s 10.05 s INJECT 24 A (X 2) 10.14 s
40 A TAP , Io 40 A 40 A TAP , Ios 24 A

CURVE SI , TMS 1.0 CURVE SI , t/T 1.0
INJECT 80 A (X 2) 10.27 s 10.13 s 10.23 s INJECT 48 A (X 2) 10.19 s
SHUNT TRIP COIL TESTED ON A 30 / 110 V DC SUPPLY.
TEST ENGINEER
S.SMART
kNAPP MILL RMU 1 and 2.xls
SECONDARY INJECTION TEST

SITE BWHW KNAPP MILL
DATE 28/10/08 TESTED BY J C PIDGEON TEST

RESULT PASS
CIRCUIT RMU 1 TYPE MG RINGMASTER RN2C
SWITCHBOARD 11 kV SUBSTATION Treated Water P/S C/T RATIO 200

1
PROTECTION TYPE VIP300 SERIAL NUMBER 100394496
RELAY 3143042FA
RELAY SETTINGS RANGE X4
O/C Is = 112.00 E/F Is = 48.00
Times for SI 10.03 Curve = SI Curve = SI
X2 VI 13.5 t> 0.30 t> 0.15
current EI 26.7 (TM =) 0.10 (TM =) 0.05
LTI 120 I>>/Is= 12.00 I>>/Is= OFF
t>> 0.03 t>> 0.03
DT 3.00 DT 3.00
Equivalent secondary current 0.56 A 0.24 A

Expected pick up value 0.672 A 0.288 A
Instantaneous trip 6.72 A N/A A
2 x setting current 1.12 A 0.48 A
Expected time at x2 set current 1.00 sec 0.50 sec
PICK UP TEST
PICK UP DROP OFF EXPECTED
SECONDARY CURRENT CURRENT CURRENT NEON
PHASE CONNECTION A A A FLAG
note
R C11-C70 1,2 0.63 0.61 0.67 Y
Y C31-C70 1,2 0.61 0.60 0.67 Y
B C51-C70 1,2 0.61 0.60 0.67 Y
E/F C11-C70 2 0.250 0.240 0.288 Y
DELAY TRIPPING TEST

INJECTION EXPECTED
SECONDARY CURRENT TIME TIME C/B
PHASE CONNECTION A SEC SEC % DIFF TRIP FLAG
note
R/Y C11-C70 1,2,4 1.12 1.11 1.00 10.67 note 3 Y
Y/B C31-C70 1,2,4 1.12 1.1 1.00 9.67 note 3 Y
B/R C51-C70 1,2,4 1.12 1.08 1.00 7.68 note 3 Y
R/Y C11-C70 1,2,5 1.12 9.49 10.03 5.38 note 3 Y
Y/B C31-C70 1,2,5 1.12 9.15 10.03 8.77 note 3 Y
B/R C51-C70 1,2,5 1.12 9.18 10.03 8.47 note 3 Y
E/F C11-C70 2,4 0.48 0.62 0.50 23.63 note 3 Y
E/F C31-C70 2,4 0.48 0.62 0.50 23.63 note 3 Y
E/F C51-C70 2,4 0.48 0.62 0.50 23.63 note 3 Y
E/F C11-C70 2,5 0.48 4.51 5.02 10.07 note 3 Y
E/F C31-C70 2,5 0.48 4.51 5.02 10.07 note 3 Y
E/F C51-C70 2,5 0.48 4.52 5.02 9.87 note 3 Y
Page 1 of 4 Treated Water PS 13/11/08 17:25

SERIAL NUMBER 100394496 CONT

INSTANTANEOUS TRIPPING TEST
TIME INST EXPECTED
SECONDARY TRIP CURRENT TIME CURRENT C/B
PHASE CONNECTION CURRENT A SEC A TRIP FLAG
note A
R/Y C11-C70 1,2 6.30 6.77 0.12 6.72 note 3 Y
Y/B C31-C70 1,2 6.30 6.77 0.13 6.72 note 3 Y
B/R C51-C70 1,2 6.30 6.77 0.12 6.72 note 3 Y
E/F C11-C70 2 N/A note 3 Y
note 1 Earth fault relay set to OFF setting to avoid tripping

note 2 Circuit breaker auxiliary used for timing (40,41)
note 3 Circuit breaker tripped
note 4 Error due to measuring a very short time using CB auxilary contacts
note 5 TM multiplier temporarly set to 10

SECONDARY INJECTION TEST

SITE BWHW KNAPP MILL
DATE 28/10/08 TESTED BY J C PIDGEON TEST

RESULT PASS
CIRCUIT RMU 2 TYPE MG RINGMASTER RN2C
SWITCHBOARD 11 kV SUBSTATION Treated Water P/S C/T RATIO 200

1
PROTECTION TYPE VIP300 SERIAL NUMBER 100394071
RELAY SETTINGS RANGE X4

O/C Is = 112.00 E/F Is = 48.00
Times for SI 10.03 Curve = SI Curve = SI
X2 VI 13.5 t> 0.30 t> 0.15
current EI 26.7 (TM =) 0.10 (TM =) 0.05
LTI 120 I>>/Is= 12.00 I>>/Is= OFF
t>> 0.03 t>> 0.03
DT 3.00 DT 3.00
Equivalent secondary current 0.56 A 0.24 A

Expected pick up value 0.672 A 0.288 A
Instantaneous trip 6.72 A N/A A
2 x setting current 1.12 A 0.48 A
Expected time at x2 set current 1.00 sec 0.50 sec
PICK UP TEST
PICK UP DROP OFF EXPECTED
SECONDARY CURRENT CURRENT CURRENT NEON
PHASE CONNECTION A A A FLAG
note
R C11-C70 1,2 0.63 0.62 0.67 Y
Y C31-C70 1,2 0.63 0.62 0.67 Y
B C51-C70 1,2 0.63 0.62 0.67 Y
E/F C11-C70 2 0.250 0.240 0.288 Y
DELAY TRIPPING TEST

INJECTION EXPECTED
SECONDARY CURRENT TIME TIME C/B
PHASE CONNECTION A SEC SEC % DIFF TRIP FLAG
note
R/Y C11-C70 1,2,4 1.12 1.1 1.00 9.67 note 3 Y
Y/B C31-C70 1,2,4 1.12 1.11 1.00 10.67 note 3 Y
B/R C51-C70 1,2,4 1.12 1.11 1.00 10.67 note 3 Y
R/Y C11-C70 1,2,5 1.12 9.31 10.03 7.18 note 3 Y
Y/B C31-C70 1,2,5 1.12 9.35 10.03 6.78 note 3 Y
B/R C51-C70 1,2,5 1.12 9.47 10.03 5.58 note 3 Y
E/F C11-C70 2,4 0.48 0.63 0.50 25.62 note 3 Y
E/F C31-C70 2,4 0.48 0.63 0.50 25.62 note 3 Y
E/F C51-C70 2,4 0.48 0.63 0.50 25.62 note 3 Y
E/F C11-C70 2,5 0.48 4.58 5.02 8.67 note 3 Y
E/F C31-C70 2,5 0.48 4.64 5.02 7.48 note 3 Y
E/F C51-C70 2,5 0.48 4.51 5.02 10.07 note 3 Y

SERIAL NUMBER 100394071 CONT

INSTANTANEOUS TRIPPING TEST
TIME INST EXPECTED
SECONDARY TRIP CURRENT TIME CURRENT C/B
PHASE CONNECTION CURRENT A SEC A TRIP FLAG
note A
R/Y C11-C70 1,2 6.30 6.94 0.13 6.72 note 3 Y
Y/B C31-C70 1,2 6.30 6.94 0.12 6.72 note 3 Y
B/R C51-C70 1,2 6.30 6.94 0.12 6.72 note 3 Y
note 1 Earth fault relay set to OFF setting to avoid tripping

note 2 Circuit breaker auxiliary used for timing (40,41)
note 3 Circuit breaker tripped
note 4 Error due to measuring a very short time using CB auxilary contacts
note 5 TM multiplier temporarly set to 10

PDT TC01 REVA 11/01/01
POWER & DISTRIBUTION TRANSFORMERS

TRANSFORMER TEST CERTIFICATE
CUSTOMER S.E.C. ORDER NO 1301 A

MANUFACTURER PDT SERIAL NO 1298161
TYPE OF COOLING ONAN FREQUENCY 50 Hz
PHASES PRIMARY 3 PHASES SECONDARY 3
PRIMARY VOLTAGE 11000 V SECONDARY VOLTAGE 433 V
PRIMARY CURRENT 104.97 A SECONDARY CURRENT 2,667 A
KVA 2,000 VECTOR GROUP Dyn11
IMPEDANCE 6.12 % NUMBER OF TAPS 5
DIAGRAM COLOUR GREY
TRANSFORMER TEST & INSPECTION DOCUMENTS ENCLOSED

TS14 DOCUMENT TRANSFORMER RATIO & VECTOR GROUP TEST
TS15 DOCUMENT TRANSFORMER INSULATION TEST
TS16 DOCUMENT TRANSFORMER WINDING RESISTANCE TEST
DECLARATION
THIS TRANSFORMER IS CONSTRUCTED TO IEC 60076
TESTED BY S.SMART
DATE 02/06/2008
DOCUMENT
TRANSFORMER RATIO & VECTOR GROUP TEST NO REV REV DATE
PDT TS14 1 11/01/2001
DATE JOB NO SERIAL NO.

02/06/2008 1301 A 1298161
RATIO TEST
AVERAGE
TRNSFORMER VOLTAGE AVERAGE LV RATIO
HV
VOLTAGE RATIO
11,000 396.00 X 15.63 = 434.26
SUPPLY VOLTAGE LV VOLTAGE TAP 1 TAP 2 TAP3 TAP 4 TAP 5

A-B 396 a-b 14.90 15.20 15.67 16.01 16.43
B-C 397 b-c 14.88 15.16 15.64 15.99 16.42
A-C 395 a-c 14.84 15.13 15.59 15.94 16.37
VECTOR GROUP TEST
JOIN 'A' TO 'a' AND SUPPLY A-B,B-C,A-C AT 397 VOLTS ON TAP SWITCH POSITION 3
A-a 0 B-a 397 C-a 396
A-b 15.66 B-b 384 C-b 396
A-c 15.60 B-c 384 C-c 383
TEST EQUIPMENT USED

RW33 , RW50
TEST ENGINEER
S.SMART
DOCUMENT
TRANSFORMER INSULATION TEST NO REV. REVISION DATE
PDT TS15 B 11/01/2001

02/06/2008 1301 A 1298161
INSULATION TEST
2500V D.C. H.V. TO L.V. WINDING & earth 7,500
TRANSFORMER
RATIO
PRE-MEGGER TEST
1000V D.C. L.V. TO H.V. WINDING & earth 6,000
H.V. H.V. TEST

11,000 24 kV AC 1 min H.V. TO L.V. WINDING & earth 46.02 m
L.V. L.V. TEST

433 2 kV AC 1 min L.V. TO H.V. WINDING & earth 0.23 m

POST-MEGGER TEST
OVERPOTENTIAL TEST
SUPPLY VOLTS 866 VOLTS ACROSS L.V. TERMINALS FOR 15 SEC AT 400Hz
PASS D FAIL
TEST EQUIPMENT USED

MEGGER RW17
H.V. TEST SET RW13 L.V TEST SET RW18 TEST ENGINEER
COMMENTS S.SMART
DOCUMENT
TRANSFORMER WINDING RESISTANCE TEST NO REV REVISION DATE
PDT TS16 C 11/01/2001

02/06/2008 1301 A 1298161
H.V. WINDINGS RESULTS L.V. WINDINGS RESULTS

A-B 567 milli a-b 803 micro
B-C 584 milli b-c 804 micro
A-C 579 milli a-c 813 micro
A-N N/A milli a-n 410 micro
B-N N/A milli b-n 409 micro
C-N N/A milli c-n 420 micro
TEST EQUIPMENT USED

RW22
COMMENTS
TEST ENGINEER
S.SMART
DOCUMENT
ADDITIONAL TESTS NO REV REVISION DATE
PDT AT01 A 20/03/2003

02/06/2008 1301 A 1298161
Transformer tested with Merlin Gerin Ringmaster type RN2C - T2/21

Ser.No. 100494496
TEST ENGINEER
S.SMART
PDT TC01 REVA 11/01/01
POWER & DISTRIBUTION TRANSFORMERS

TRANSFORMER TEST CERTIFICATE
CUSTOMER S.E.C. ORDER NO 1301 B

MANUFACTURER PDT SERIAL NO 1298160 1301 B
TYPE OF COOLING ONAN FREQUENCY 50 Hz
PHASES PRIMARY 3 PHASES SECONDARY 3
PRIMARY VOLTAGE 11000 V SECONDARY VOLTAGE 433 V
PRIMARY CURRENT 104.97 A SECONDARY CURRENT 2,667 A
KVA 2,000 VECTOR GROUP Dyn11
IMPEDANCE 6.09 % NUMBER OF TAPS 5
DIAGRAM COLOUR GREY
TRANSFORMER TEST & INSPECTION DOCUMENTS ENCLOSED

TS14 DOCUMENT TRANSFORMER RATIO & VECTOR GROUP TEST
TS15 DOCUMENT TRANSFORMER INSULATION TEST
TS16 DOCUMENT TRANSFORMER WINDING RESISTANCE TEST
DECLARATION
THIS TRANSFORMER IS CONSTRUCTED TO IEC 60076
TESTED BY S.SMART
DATE 04/06/2008
DOCUMENT
TRANSFORMER RATIO & VECTOR GROUP TEST NO REV REV DATE
PDT TS14 1 11/01/2001

04/06/2008 1301 B 1298160 1301 B
RATIO TEST
AVERAGE
TRNSFORMER VOLTAGE AVERAGE LV RATIO
HV
VOLTAGE RATIO
11,000 394.67 X 15.58 = 434.33
SUPPLY VOLTAGE LV VOLTAGE TAP 1 TAP 2 TAP3 TAP 4 TAP 5

A-B 395 a-b 14.91 15.26 15.62 15.98 16.40
B-C 395 b-c 14.88 15.25 15.58 15.97 16.40
A-C 394 a-c 14.88 15.24 15.55 15.96 16.36
VECTOR GROUP TEST
JOIN 'A' TO 'a' AND SUPPLY A-B,B-C,A-C AT 394 VOLTS ON TAP SWITCH POSITION 3
A-a 0 B-a 394 C-a 394
A-b 15.63 B-b 381 C-b 394
A-c 15.59 B-c 381 C-c 381
TEST EQUIPMENT USED

RW33 , RW50
TEST ENGINEER
S.SMART
DOCUMENT
TRANSFORMER INSULATION TEST NO REV. REVISION DATE
PDT TS15 B 11/01/2001

04/06/2008 1301 B 1298160 1301 B
INSULATION TEST
TRANSFORMER
RATIO
PRE-MEGGER TEST
H.V. H.V. TEST

11,000 24 kV AC 1 min H.V. TO L.V. WINDING & earth 46.16 m
L.V. L.V. TEST

433 2 kV AC 1 min L.V. TO H.V. WINDING & earth 0.23 m

POST-MEGGER TEST
OVERPOTENTIAL TEST
SUPPLY VOLTS 866 VOLTS ACROSS L.V. TERMINALS FOR 15 SEC AT 400Hz
PASS D FAIL
TEST EQUIPMENT USED

MEGGER RW17
H.V. TEST SET RW13 L.V TEST SET RW18 TEST ENGINEER
COMMENTS S.SMART
DOCUMENT
TRANSFORMER WINDING RESISTANCE TEST NO REV REVISION DATE
PDT TS16 C 11/01/2001

04/06/2008 1301 B 1298160 1301 B
H.V. WINDINGS RESULTS L.V. WINDINGS RESULTS

A-B 585 milli a-b 820 micro
B-C 587 milli b-c 824 micro
A-C 589 milli a-c 836 micro
A-N N/A milli a-n 424 micro
B-N N/A milli b-n 421 micro
C-N N/A milli c-n 436 micro
TEST EQUIPMENT USED

RW22
COMMENTS
TEST ENGINEER
S.SMART
DOCUMENT
ADDITIONAL TESTS NO REV REVISION DATE
PDT AT01 A 20/03/2003

04/06/2008 1301 B 1298160 1301 B
Transformer tested with Merlin Gerin Ringmaster type RN2C - T2/21

Ser.No. 100394071
TEST ENGINEER
S.SMART
Section 10 Equipment, Manufacturers & Suppliers
Contents
10.1 Introduction
10.2 Manufacturers and Suppliers Details
10.3 Equipment Data Sheets
10.1 Introduction
This section gives detail of the equipment manufacturers / suppliers together with
any technical data for the significant systems and equipment installed.
Manufacturers / Suppliers Schedule
Manufacture / Supplier Equipment Section

Power & Disrtribution Transformers Ltd. Transformers 10.2.1
Delta Cables Steel Wired Amoured 10.2.2
Richard Wilson (Dencol) Ltd. Ring Main Units 10.2.3

10.2.1 Manufacturers and Suppliers Information
Manufacturer
Power & Distribution Transformers Limited (PDT)
Equipment Category Distribution Equipment

Manufacturers Address Westland Square
Leeds
LS11 5SS
0113 271 7588

Telephone Number
Fax Number 0113 277 5124
Supplier Direct Sale

Suppliers Address As Above
Telephone Number 0113 271 7588

Fax Number 0113 277 5124
Equipment Ranges Used on this Project

Ref: Description
1298161 1000kVA Transformer
1298160 1000kVA Transformer

Manufacturer
Delta Crompton Cables Limited
Equipment Category Distribution Equipment

Manufacturers Address Millmarsh Lane
Brimsdon
Enfield
Middlesex EN3 7QD
020 8804 2468
Telephone Number
Fax Number 020 8443 1923
Supplier Cleveland Cable Company Ltd

Suppliers Address Riverside Park Road
Middlesbrough
TS2 1QW
Telephone Number 01642 241133
Fax Number 01642 226171

Ref: Description
6944X50 500 XPLE SWA
32BW TERMS Cable Glands
6944XPLE Red HV 95mm 3C LSF
HV Termination ALI 95MM Gland Kit

Manufacturer
Richard Wilson (Dencol) Ltd.
Equipment Category Merlin Gerin

Manufacturers Address London and South East
Schneider Electric Ltd.
2nd Floor,
408 Stran,
London.
WC2R 0NE
0870 608 8 608
Telephone Number
Fax Number 0870 608 8 606
Supplier Richard Wilson (Dencol)Ltd.

Suppliers Address Westland Square
Leeds
LS11 5SS
Telephone Number 0113 271 7588

Fax Number 0113 277 5124

Ref: Description
RN2C-T2/21 Ring Main Unit

10.3 Equipment Data Sheets

Section 11 CDM Health and Safety Information

Contents
11.1 Health and Safety Plan
11.2 Risk Assessments & COSHH Assessments
11.3 Method Statements Associated With This Contract
11.1 Health and Safety Plan
The health and safety plan for the project is filed as the following page.

11.2 Risk Assessments & COSHH Assessments

The following risk assessments are included in this section:
Ref Company
Topic Date
SEC Ltd
Stage 1 risk assessment 26/04/08
SEC Ltd
Stage 1 risk assessment 09/10/08
SEC Ltd
Generic risk assessment 26/04/08
The following COSHH assessments are included in this section:
Ref Assessment By
Product Ref

11.3 Method Statements Associated With This Contract

The following method statements are included in this section:
Ref Assessment By
Task Ref
1 Marsh Plant
Crane transformer into position
2 Cleveland Cables
Unloading of Materials 33
3 SEC Ltd.
Position Transformer SR
4 SEC Ltd.
Temporary Joint SR
5 SEC Ltd.
LV Cables to transformer SR

Section 12 Drawings Register
The following as-built drawings are included in this manual.
Ref: Title Revision
SSE /HO/65/037 Typical supply chamber layout

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Operations & Maintenance Manual

Treated Water Pump House

Treated Water Pump House

Issue 1 Revision A Date 10/06/09

Prepared by SEC Bournemouth

Checked by S. Ramsier For SEC

Project Ref: 163021 Operations & Maintenance Manual Section 1 Page 1

1. Introduction and O & M Manual Issue/Revision Chart

3. Specialist Systems Technical Data

10. Manufacturers & Suppliers Details

11. CDM Health and Safety Information

12. Schedule of Drawings

Project Ref: 163021 Operations & Maintenance Manual Section 1 Page 2

O & M Manual Issue/Revision Chart

Issue/Revision Details Of Alterations Sect Rev Copies

Project Ref: 163021 Operations & Maintenance Manual Section 1 Page 3

1.1 Southern Electric Contracting Ltd.

1.2 Office Details

1.3 Abbreviations Used in this Manual

1.4 Using This Manual

1.5 Health and Safety at Work

1.1 Southern Electric Contracting Ltd.

Southern Electric Contracting Ltd (SEC) is a multi-faceted company at the leading

SEC is committed to service excellence and this commitment is your safeguard.

Southern Electric Contracting Ltd is part of the SSE Contracting Group.

Project Ref: 163021 Operations & Maintenance Manual Section 1 Page 4

1.2 Office Details

Head Office and Registered Office

District Office Responsible for Project

Contact Name: Steve Ramsier

1.3 Abbreviations used in this manual

CPC Circuit Protective Conductor

MCB Miniature Circuit Breaker

MCCB Moulded Case Circuit Breaker

PSU Power Supply Unit

UPS Uninterruptible Power Supply

PPE Personal Protective Equipment

COSHH Control of Substances Hazardous to Health

I.E.E Institute of Electrical Engineers

HRC High Rupturing Capacity

Project Ref: 163021 Operations & Maintenance Manual Section 1 Page 5

1.4 Using This Manual

Any persons employed to work on the installation and systems

1.5 Health & Safety At Work

1. It is the duty of every employer:

a. to ensure as so far as is reasonably practical the health, safety and

b. to provide information necessary for (a) above.

3. It is the duty of every employee while at work:

4. In undertaking maintenance works, it should be noted that compliance with at

Health and Safety at Work Act 1974 and Supplementary Regulations

Project Ref: 163021 Operations & Maintenance Manual Section 1 Page 6

FAILURE TO COMPLY WITH RELEVANT HEALTH AND SAFETY AT

5. Where appropriate to the work, protective equipment (goggles, screens,

8. Before working on electrical equipment which could present a disruption of

12. Anyone in control of industrial or commercial premises must prevent or render

Project Ref: 163021 Operations & Maintenance Manual Section 1 Page 7

regulations, a responsible and readily available person trained in First Aid

Project Ref: 163021 Operations & Maintenance Manual Section 1 Page 8

Section 2 System Description

2.1 General Project Overview

2.2 Scope of Works

2.3 Building Description

2.4 Health & Safety

2.5 Detailed Engineering

Knapp Mill WTW Treated Water Pump House HV Supply O & M Manual

Knapp Mill WTW Treated Water Pump House HV Supply O & M Manual