O & M Manual1-Traction

 BANGALORE METRO RAIL CORPORATION LIMITED
BANGALORE METRO RAIL CORPORATION LIMITED

TRACTION
OPERATION & MAINTENANCE MANUAL
2010
CONTRACT: EP1-CC
M/s.  LIMITED, BANGALORE
 OPERATION & MAINTENANCE MANUAL Page 01

 BANGALORE METRO RAIL CORPORATIOn limited

TABLE OF CONTENTS:
Sl.No. Description of Content Page No.
CHAPTER -I
1.0 GENERAL OVERVIEW
1.1 Introduction 12 - 14
1.2 66 kV Network 15 - 15
1.3 RSS Configuration 15 - 16
1.4 33 kV Distribution Network 17 - 17
1.5 Auxiliary Substations 18 - 18
1.6 Traction Substations 18 - 18
1.7 Third Rail & Stinger System 19 - 19
1.8 Earthing, Bonding & Stray Current Management 20 - 21
1.9 SCADA, ETS & Power Supply Protection System 21 - 22
2.0 ORGANIZATION OVERVIEW
2.1 Organization Chart 23 - 23
2.2 Duties & Responsibilities 24 - 30
3.0 SAFETY
3.1 Safety Information 31 - 33

CHAPTER-II
1.0 RECEIVING SUBSTATIONS
1.1 General 35 - 35
1.2 RSS Scheme 35 -35
1.3 RSS Layout 36 – 36
1.4 RSS Operation Logic 37 - 38
1.5 66 kV Feeders & RSS Protections 39 – 41
1.6 Metering at 66 kV Level 42 - 42
2.0 RSS EQUIPMENTS 43 - 43
2.1 66/33 kV Power Transformer
2.1.1 Technical Specification 44 - 49
2.1.2 Operation of Transformer 50 – 50
2.1.3 Energization Procedure 50 - 51
2.1.4 Energization 51 - 51
2.1.5 General Supervision & Maintenance 52 - 54
2.1.6 Maintenance Schedule 55 - 57

2.2 66 kV Circuit Breaker
2.2.1 General Description 58 - 58
2.2.2 Technical Specifications 59 – 61
2.2.3 Operating Mechanisms 62 – 63
2.2.4 Closing & Opening Operations 64 – 64
2.2.5 Auto-Reclosing 64 – 64
2.3 66 kV Current Transformer
2.3.1 General Description 67 – 68
2.3.3 Operation Parameters 70 - 70
2.3.4 Filling Procedure of CT with Gas – SF 6 71 – 72
2.3.5 General Supervision & Maintenance 73 - 73
2.4 66 kV Potential Transformer
2.4.3 Filling Procedure of PT with Gas - Nitrogen 79 – 79

2.4.4 Oil Filtration 79 – 80
2.4.5 General Supervision & Maintenance 80 – 81
2.5 66 kV Isolator
2.5.2 Technical Specifications 89 - 90
2.5.3 Isolator Installation Procedure 91 - 91
2.5.4 Earth Switch Installation Procedures 92 - 92
2.5.5 Operating Instruction 93 - 93
2.5.6 Maintenance 93 - 95
2.6 Neutral Grounding Resistor
2.6.3 Operation Mechanism 99 – 100

CHAPTER - III
1.0 AUXILIARY SUBSTATIONS
1.1 Overview 105 - 105
1.2 ASS Types 105 – 106
2.0 TRACTION SUBSTATIONS
2.1 Overview 107 - 107
2.2 TSS Types 108 - 109
2.3 ASS Equipments 109 – 109
2.4 TSS Equipments 109 - 109
2.5 33 kV Switchgear
2.5.2 Structure & Design of Panel Compartments 111 - 112
2.5.3 Technical Specifications 113 - 119
2.5.4 Operating Mechanism 120 - 121
2.5.6 Maintenance Schedule 123 – 124

Sl.No. Description of Content

Page No.
2.6 Dry Type Transformer
2.6.1 Auxiliary Transformer (200 kVA) 125 - 125
2.6.2 Technical Specifications of 200 kVA Aux. Transformer 126 - 128
2.6.4 Technical Specifications of 500 kVA Aux. Transformer 130 – 132
2.6.6 Technical Specifications of 2000 kVA Aux. Transformer 134 - 136
2.6.7 Transformer Protection 136 – 137
2.6.8 Connections 137 - 138
2.6.9 Parallel Operation 138 – 138
2.6.10 Ground Connection 138 - 138
2.6.11 Tap Connection 139 – 139
2.6.12 Cable Connection 139 – 139
2.6.13 Bus Connection 140 – 140
2.6.14 Pre-Operation Checks 140 - 141
2.6.15 Operation of Transformer 141 - 141


Page No.
CHAPTER - IV
1. THIRD RAIL
1.1 Installation of Brackets 146 - 147
1.2 Installation of Insulators 148 - 149
1.3 Installation of Conductor Rails 150 – 153
1.4 Installation of Splice Assemblies 154 - 155
1.5 Installation of Expansion Joints 156 - 160
1.6 Installation of Anchor Blocks 161 – 164
1.7 Installation of Cover Fasteners (Clips) 165 - 166
1.8 Installation of Ramps 167 – 170
1.9 Installation of connector plates, Power Feeds 171 - 172
1.10 Installation of Insulted Joint Assemblies 173 – 174
1.11 Installation of UPVC- and GRP Protective Covers 175 – 176
1.12 Installation of UPVC- and GRP Insulator Covers 177 – 177
1.13 Structure Dimensions Control 178 - 178
2.0 Maintenance 179 - 179
2.0.2 Troubleshooting 180 - 186


Page No.
CHAPTER - V
1. SCADA
1.1 Basic Operation 188 - 194
1.2 Control of Objects 195 – 198
1.3 Limit Supervision 199 – 199
1.4 Control System 200 - 201
1.5 Maintenance Schedule of RTU 201 - 201
1.6 Glossary & Abbreviation 202 - 203

CHAPTER - I

1.0 General Overview

1.1 Introduction
1.1.1 Bangalore Metro Rail -- Phase 1 comprises of two corridors; the East- West (E-W) Corridor, of
approximately 18.1 km length with 17 stations , out of which 5 are underground stations and the
North-South (N-S) Corridor of approximately 23.83 km length with 23 stations, out of which 3 are
underground stations.
1.1.2 Two corridors are inter-connected for interchange of train rakes at Majestic underground Station,
purely for operational purposes. The mode of traction is 750V dc Third Rail.
The network map of the Phase-I of Bangalore MRTS is shown in Figure 1.1
Fig. 1.1: Schematic representation of Phase-I of Bangalore Metro

The details of station names in respective corridors of BMRCL Phase-I network are shown in Table 1.1
below.
Table 1.1: Stations’ details
SN Corridor Station Name
1 Mysore Road Terminal
2 Deepanjali Nagar
3 Attiguppe
4 Vijayanagar
5 Hosahalli
6 Magadi Road
7 City Railway Station
8 Kempegowda
9 East - West Corridor Sir M Visveshwaraya
10 Vidhan Soudha
11 Cubbon Park
12 Mahatma Gandhi Road
13 Trinity Circle
14 Halasuru
15 Indiranagar
16 Swami Vivekananda Road
17 Baiyappanahalli

SN Corridor Station Name
1 Nagasandra
2 Dasarahalli
3 Jalahalli
4 Peenya Industry
5 Peenya
6 Yeshwantpur Industry
7 Yeshwantpur
8 Sandal Soap Factory
9 Mahalakshmi
10 Rajaji Nagar
11 Kuvempu Road
12 North - South Corridor Srirampura
13 Sampige Road
14 Chickpete
15 Krishna Rajendra Market
16 National College
17 Lalbagh
18 South End Circle
19 Jayanagar
20 Rashtreeya Vidyalaya Road
21 Banashankari
22 Jaya Prakash Nagar
23 Puttenahalli

1.2 66 KV Network
1.2.1 KPTCL is the nodal agency for the supply of power for different utilities. Four RSSs are envisaged
for receipt of power from KPTCL for further distribution to Traction and Auxiliary networks of
Metro corridor.
SN Corridor RSS Locations Feeding Grid No. Of Incoming

Substation Feeders
RSS-1 Baiyappanahalli HAL 220/66kV Substation (1 x 66 kV Feeder)

RSS
Hoody 400/220/66kV (1 x 66 kV Feeder)
EAST- Substation
RSS-2 WEST Vrishbhavathi Valley (1 x 66 kV Feeder)

CORRIDOR 220/66kV substation
Mysore Road RSS
REMCO substation (1 x 66 kV Feeder)
(220/66 kV)
RSS-3 Peenya RSS Peenya (SRS) 400/220/66 (2 x 66 kV Feeder)

NORTH- kV substation
SOUTH
RSS-4 CORRIDOR Puttenhalli RSS Khoday 220/66kV (2 x 66 kV Feeder)
substation
1.3 RSS Configuration

1.3.1 The incoming power supply is at 66 KV level. Each RSS will have feed from two different feeders.
Each feeder will consist of one circuit (1 C x 630 Sq. mm Aluminium). The RSS at Baiyappanahalli,
Peenya and Puttenhalli are AIS type. Whereas, the 66 KV switchgear at Mysore Road RSS is GIS
type.
1.3.2 Each RSS will consist of two transformer bays, of which one would be a hot stand-by. The
transformer will convert the 66 KV level voltages to 33 KV and feed to the Ring circuits.
1.3.3 The power at 33 KV level will be distributed among the Auxiliary and Traction substations for
Auxiliary and Traction loads.
1.3.4 The electric traction supply system has to be continuous without any kind of interruption. Hence,
maximum level of redundancy has been maintained. In this regard, one feeder – 66 kV has been
kept as a hot stand-by, in case, one feeder fails, the other feeder can be brought into service to
continue power supply.

Figure 1.2: Bulk Supply Arrangement

1.4 33 kV Distribution Network
1.4.1 The 66kV power supply received from KPTCL is stepped down to 33kV level at the four RSSs of
BMRCL. The 33kV power supply drawn from RSSs of each corridor is distributed along the
alignment through 33kV Ring main cable network for feeding to traction and auxiliary loads.
1.4.2 The 33kV feeds from RSSs are fed to TSSs and ASSs at Peenya station (from Peenya RSS),
Baiyappanahalli station (from Baiyappanahalli RSS), Mysore Road station (from Mysore Road RSS)
and Puttenhalli station (from Puttenhalli RSS).
1.4.3 Power supply at 33kV is distributed to various traction substations as well as auxiliary substations
located in stations, by means of a 33kV ring main feeder network having 4 circuits in trefoil
formation of size [3 x (1C x 240) Sq. mm Cu] – two each for 33kV Power Supply to Traction
Substations (TSS) and Auxiliary Substations (ASS). Complete segregation of traction and auxiliary
supplies at 33kV cable distribution network is maintained. 33 kV power supply for Traction Power
is by closed loop and for Auxiliary power, it is by Open loop system.
1.4.4 Power supply at 33kV is also distributed to Depot / Workshop (Baiyappanahalli and Peenya) for
Traction and Auxiliary substations through two separate 33kV cable feeders from the respective
RSS.
1.4.5 For provision of more flexibility of power supplies in emergency situations, the 33kV distribution
network of both corridors are available for interconnection through Circuit Throw Over (CTO) at
Kempegowda Station (two level underground station with passenger interchange) through 33kV
cables. These interconnections will make it possible to transfer power from one corridor network
to another corridor network in emergency situations for both the traction and auxiliary loads.

1.5 Auxiliary Substations
1.5.1 RSS are equipped with 2 x 200 kVA 33 kV/415 V Dry type Auxiliary Transformers for LT Supply.
1.5.2 Each elevated and at-grade station is provided with one Auxiliary Substation (ASS) having 33 kV /
415V, 2 x 500 kVA dry type transformers.
1.5.3 Each underground station is provided with two Auxiliary Substations ASS1 and ASS2, each with
33 kV / 415 V, 1 x 2000 kVA dry type transformers.
1.5.4 In each Depot, auxiliary substation having 33 kV / 415 V, 2 x 2000 kVA dry type transformers is
provided. In addition, another auxiliary substation having 2 x 500 kVA dry type transformers is
provided for Operation Control Center in Byappanahalli Depot.
1.5.5 In normal scenario, the two transformers of ASS for elevated / at-grade stations and two ASSs of
underground station is receiving power supply from different sources. Since one transformer is in
hot standby and each receiving supply from different source, either of ring cable fault or
transformer fault will not impact the station supply.
1.6 Traction Substations
1.6.1 33 kV / 750 V dc Traction Substations (TSSs) is provided at stations along the corridor, where the
33kV is transformed and rectified to 750V dc for feeding the Third Rail, from where the rail cars
will finally draw power for propulsion.
1.6.2 Each traction substation is receiving power at 33kV from the 33kV ring feeder. Normally, every
TSS has 2 switchgear feeders, for loop-in-loop-out of 33kV ring main feeder, which provides
power to 33kV busbar. Rectifier transformer(s) are fed from this busbar.
1.6.3 The feeding to TSSs is with close ring systems – i.e. from the respective RSS two 33kV feeders
(one from each half of 33kV busbar in RSS) to feed alternate TSSs and the ring is closed at
appropriate location, e.g. at Kempegowda for rings from all the RSSs.
1.6.4 Separate TSSs is provided for Depots and in the normal scenario the complete isolation of
mainline and depot supplies can be achieved. The depot TSSs (and ASSs) are fed from respective
RSSs through 33kV ring main feeders from the two halves of the RSS 33kV busbar.
1.6.5 This arrangement of TSS feeding ensures that one ring main cable fault will not put any of the
TSS out of service. The 750V dc is fed to the third rail system through high-speed circuit breaker
(HSCBs) and disconnecting switches are incorporated for sectionalizing the third rail as per the
operational requirements.

1.7 Third Rail and Stinger System
1.7.1 The Third rail system at 750 V DC is utilized for transferring power to the Rolling Stock. The
traction power is transferred via the vehicle collector shoes by contacting the surface of the
contact rail from underneath. The third rail is made of an aluminium body designed for a nominal
current of 4500A and a stainless steel contact path for current transfer to the collector shoes.
1.7.2 Components
The Third Rail system consists basically of the following main components:
a) Conductor Rail
b) Splice Joint assembly for third rail
c) Expansion Joint
d) Anchor Assembly
e) Insulated Joint assembly
f) Power Feed Assembly
g) Ramp
h) Support Assembly
i) Protective Cover system
1.7.3 The conductor rails are rated at a nominal resistance of max. 0.007 Ω / km at a current of 4500
A. Rail lengths are of 15m with pre-drilled holes for splice joints. The typical configuration of the
conductor rail is – Aluminium: EN-AW 6101B & Stainless Steel: 1.4016, X6Cr17, 17% Chromium.
1.7.4 The conductor rail is symmetrical around the vertical centre line. The web recess of the rail has
facing tapered surfaces for the purpose of amplifying the compression load of the clamping bolts
of connections on the current carrying surface of the connection.
1.7.5 The third rail system as used for traction power supply along the electrified tracks is replaced in
train inspection tracks inside the workshop by ceiling conductor rails. The power is provided to
the vehicles by cables with special contacts simply known as stingers.
1.7.6 The power supply from the suspended rail to the vehicle is made via a current collecting trolley.
This trolley, running on the I-profiled conductor rail is provided with an adequate cable with a
special plug. When not in use, the stingers down-end shall be attached to cable clamps in an up-
right position.
1.7.7 The inspection tracks inside the workshop are provided with individual stinger lines, whereas the
other depot tracks are equipped with regular conductor rail equipment.

1.8 Earthing, Bonding and Stray Current Management
1.8.1 The earth mat design and installation conforms to IEEE 80-2000.
1.8.2 The following parameters have been taken into account for earth mat.
a) Magnitude of fault current
b) Duration of fault
c) Soil resistivity
d) Resistively of surface material
e) Earthing mat geometry
f) Material of earth mat conductor
g) Shock duration
1.8.3 Earth mat for each receiving substations are installed individually. The earth mat is installed as
per the site conditions and ensures a low over all resistance (not more than 0.5 ohms) and a
current carrying capacity consistent with the fault current magnitude.
1.8.4 Short Circuit Level: - The short circuit current for the Earth mesh design at RSS has been taken as
40 KA. TSSs are designed for 35 kA and the ASS for 17.5 kA.
1.8.5 Duration of Fault Current: - As per IEEE 80-2000, the short term rating of most of the equipment
is based on 1.0 second duration of fault. Therefore, 1 second has been adopted as the duration
of fault in the calculations to determine the size of conductor for the earth mat.
1.8.6 The Grid Earth resistance has been taken as follows:
Sl. Location Grid Resistance (Ohms)

No.
1. Receiving Substations 0.5
2. Auxiliary Substations 1.0
3. Traction Substations 1.0
1.8.7 To address the stray current corrosion problem associated with the dc traction system, the
traction return circuit (running rails) is floating with respect to the earth on the mainlines.
Running rails are insulated from the structure to comply with the requirements of EN 50122-2.
1.8.8 For depots, however, for the safety reasons of workmen, the traction return system is earthed.
The running rails of Depots are electrically separated from mainlines through Insulated Rail Joints
(IRJ). These IRJs are placed in-between the main line and the depot line to isolate them from
each other by a length more than a full train length with six cars.

1.8.9 Short Circuiting Devices at each station (located in ASS-TSS room) are provided for safety
reasons i.e. temporarily short circuiting the running rails to earth in case of rise of running rail
potential exceeds prescribed limits as per EN 50122-1.
1.8.10 All the structure parts are connected to station earth mats and for this purpose Structure Earth
Cable (200 mm2 copper), linking all mainline earth mats, is provided all along the corridor for both
UP and DN lines (one on each of the parapet).
1.8.11 The station platform surface is insulated for a width of 2.5 m from the edge of the platform.
1.9 SCADA, ETS & Power Supply Protection System
1.9.1 The purpose of the SCADA system is remote monitoring and control from the Operational Control
Centre (OCC) and Backup Control Centre for all the power supply installations of the Phase I of
Bangalore Metro Rail Corporation, which consists of both the corridors and the Depots. The
Operational Control Centre (OCC) is situated in the Baiyappanahalli Depot. The Backup Control
Centre is situated in the Peenya Depot.
1.9.2 The Engineering Controller (ECO) is stationed at OCC. The ECO carries out the following main
functions:
a) It monitors the condition of the entire power supply network.
b) It energises or de-energises the different electrical sections of the auxiliary network in case of
demand.
c) It energises or de-energises the different electrical sections of the traction network in case of
demand of traffic operator or maintenance staff.
d) It segregates the faulty section in the event of a fault in auxiliary or traction network.
e) It operates the system in such a manner to arrange alternative feeds from the healthy system.
f) It identifies and communicates the fault and faulty section to concerned maintenance staff.
g) It issues and cancels the blocks on individual equipments and system for maintenance.
h) It restores the entire system after attending to faults.
i) It monitors several electrical parameters (voltage, power energy ...)
j) It prints a pre-determined log of events and data.
k) It provides analysis of normal operations as well as events to the management.

l) It provides simultaneous maximum demand of all the 4 RSSs for revenue billing.

1.9.3 For protection, interlock and metering of the equipment, protection control unit (PCU) i.e. Digital
Protection Control System (DPCS) is installed on all switchgear panels. It operates the vital
components and works as the interface with the remote SCADA system.
1.9.4 The communication between OCC SCADA and the RTUs at the power installation ends viz. RSSs,
ASSs, TSSs and other location, is achieved through OFC network. It monitors and logs the various
voltages, currents, power factor, maximum demand, power consumption and status of various
equipments and provides automated control throughout the system at the OCC/BCC through the
SCADA system.
1.9.5 The SCADA also has the provision for plugging in a portable control console (laptop) with the
RTU. It can operate and monitor the status and alarm conditions of all equipments from this local
control console.
1.9.6 An Emergency Trip System (ETS) is provided at the each end of the station platforms, cross
passage in tunnels and in depots as per the requirement of NFPA 130. Traction supply power-off,
in case of emergency, is achieved through integrating ETS with SCADA system.
1.9.7 ETS consists of ETS stations (ETS Boxes) and the RTU, which is a part of the SCADA System.
Upon activation of ETS, it proceeds through a pre-determined programme of operation of circuit
breakers and relevant interrupters to de-energise the third rail sections. Further, it has an
interface with signalling and the essential interlocking to prevent any train coming on directly or
through a cross over leading to the affected third rail section where ETS is activated.

2.0 ORGANISATION OVERVIEW

2.1 Organisation Chart
2.1.1 The organizational chart of traction department is as follows:
Director (Operation and Maintenance)
GM (Maintenance)
DGM (Electrical)
Manager (Traction)
AM (SCADA) AM (Traction Line -1) AM (Traction Line -2)
SSE/SE (SCADA) SSE/SE (Traction) SSE/SE (Traction)
ASE/JE (SCADA) ASE/JE (Traction) ASE/JE (Traction)
Maintainers (SCADA) Maintainers (Traction) Maintainers (Traction)
Unskilled Unskilled Unskilled

2.2 Duties & Responsibilities

2.2.1 GENERAL MANAGER (MAINTENANCE)
2.2.1.1 General Manager (maintenance) is the head of maintenance related activities. He is overall
responsible for all administrative as well as technical decisions, cadre controlling,
establishment matters and also for the works to be executed by the department. He will be
assisted by DGM (Elect.) and other hierarchy down below.
2.2.1.2 The General Manager (Maintenance) also functions as Electrical Inspector to Government as
defined in section 36(1) of Indian Electricity Act -1910, in respect of all high voltage electrical
installations and equipment owned by Bangalore Metro Railway Corporation Limited (BMRCL).
This includes all electrical high voltage installations in BMRCL including transmission lines,
feeder lines, traction as well as auxiliary substations, 33 KV network and 750 V dc systems.
He is responsible for administration of the Electricity Rules in BMRCL.
2.2.1.3 In regard to electric traction installations, in capacity to Electrical Inspector to the

Government, GM (Maint.) mainly performs the following activities:
a) Approval of the layout and design of the substations, 750 V dc installations etc conforming
to the Indian Electricity act and rules.
b) Inspection of the completed installations, either personally or through his nominated

representative in order to ensure compliance of all safety as well as statutory and
subsidiary requirements.
c) Approval for energization of the installation.
d) Statutory requirement of inspection of the installations periodically under rule 46 of the

Indian Electricity Rules.
e) Investigations of electrical accidents and taking remedial measures to prevent in future.
f) Submission of annual report to Central Electricity Authority.

2.2.2 DEPUTY GENERAL MANAGER (ELECTRICAL)
Deputy General Manager (Electrical) designated as DGM (Elect.) is answerable to GM (Maint.)

for all the electrical maintenance related activities. His duties are to be assigned by GM
(Elect.), however, main duties will include the following:
2.2.2.1 Deal with all correspondence except those which involve policy matters and expression of
opinion on behalf of BMRCL.
2.2.2.2 Exercise administrative and technical control for efficient planning, designing, safety and
economic operation as well as scheduled/predictive maintenance of the traction system so as
to maintain highest level of reliability and availability of the assets for regular operation of the
trains.
2.2.2.3 In case of breakdowns/accidents, take prompt and energetic action to normalize the services
at the earliest possible time and take up the enquiry to investigate the cause of the problem
along with taking remedial measures to prevent the re-occurrence.
2.2.2.4 Co-ordinate effectively with officers of other departments in BMRCL in connection with the
items of common interest.
2.2.2.5 Maintain liaison with the Power Supply Authorities in regard to tariff, continuity of supply and
policy matters etc.
2.2.2.6 Keep close watch on day to day performance of traction system and initiate/implement
preventive maintenance where ever required based on experience or otherwise.
2.2.2.7 Investigate the failures and take corrective measures to prevent in future.
2.2.2.8 Plan the cadre requirements including recruitments, promotions, training etc well in time.
2.2.2.9 Initiation and effective technical scrutiny for items for inclusion in works- program.
2.2.2.10 Ensure timely initiation and procurement of stores required for proper operation and
maintenance of Traction system, close co-ordination with stores/finance department etc. for
the same.
2.2.2.11 Arrange for standardization of stores as required including preparation of drawings,

specifications etc.
2.2.2.12 Development of vendors for stores supply
2.2.2.13 Study and analyze the periodic statistical parameters and take measures to improve the same.
2.2.2.14 Monitor energy consumption, power factor and maximum demand at various installations on
BMRCL and take appropriate measures for efficient utilization of electrical energy as well as to
contain the energy cost.

2.2.2.15 Budgeting and control over expenditure on maintenance repair and staff costs.
2.2.2.16 Keep in touch with advance technical developments so as to identify for implementation on
BMRCL for achieving further safety, efficiency, reliability and economy.
2.2.2.17 Plan long term strategy in regard to maintenance/operation requirements.

2.2.3 MANAGER (TRACTION)
Manager (traction) is the officer who is direct in -charge of the traction distribution network
system and responsible for all technical and organizational matters connected with the
efficient maintenance and operation of power supply installations and SCADA system. He
should be well acquainted with the technical details, performance ratings, operation and
maintenance schemes. His main duties are as follows:
2.2.3.1 General planning and supervision to ensure efficient and safe maintenance and operation of
traction installations in accordance to the prescribed norms and schedules.
2.2.3.2 Study of day to day technical and organizational problems related to operation/maintenance
and initiate appropriate measures to deal with it.
2.2.3.3 Man power planning to ensure efficient and economical maintenance.
2.2.3.4 Analysis of failures and take remedial measures to control, in case the failures are attributable
to design related or can be contained by way of adopting improved technology, proposal to
be moved accordingly to apprise higher authorities.
2.2.3.5 Monitor the progress and successful implementation of all the approved modifications and
analysis of efficacy of such modifications.
2.2.3.6 Monitor and ensure availability of spare parts/ stores required for maintenance and initiation
of procurement action well in advance.
2.2.3.7 Monitor the performance of various equipment to assess their anticipated life and initiate
timely proposals for their repair/replacement.
2.2.3.8 Overall co-ordination with other departments to plan better utilization of the assets and
planning of maintenance works including materializing the concept of integrated maintenance.
2.2.3.9 Inspections of his jurisdiction are as under:
a) Detailed inspection of all the assets as per schedule
b) Frequent surprise inspections including night inspections covering all the related installations
c) General inspection of all the subordinate offices under his control, at least one once in three
months including test checks of stores, tools/plants etc.
d) To ensure compliance of the instructions issued by way of inspections and other directives
2.2.3.10 Liaison with the power supply authorities in regard to the matters which can not be dealt at
lower level
2.2.3.11 Arrange adequate training of staff so as to adopt correct and effective maintenance and
operational practices

2.2.3.12 Careful preparation of budget for traction installations and control over expenditure
2.2.3.13 Scrutiny and passing of traction power supply bills, study of the energy consumption ,
maximum demand readings and liaison with rolling stock section to keep these expenditures
under effective control
2.2.3.14 Special watch on the adequacy and alertness of the organization for dealing with failures and
breakdowns, personal supervision of operations in the event of major failures affecting train
operation or outage of essential equipment.
2.2.3.15 Close association for tests and trials in the area under his control and submission of reports
2.2.3.16 Ensuring by surprise and periodical inspections that the provisions/ procedures laid down in
general and subsidiary rules, manuals, departmental codes, circulars and other orders are
circulated down below at the earliest and are being implemented in true manner & sprit.
2.2.3.17 Periodical meetings to review the performance and for enhanced co-ordination among traction
maintenance staff.

2.2.4 ASSISTANT MANAGER (TRACTION)
Assistant manager (Traction) is the immediate in-charge in the field for all the maintenance
and operation activities so that those are followed timely in efficient and safe manner as per
schedule as well as per requirement. In addition to assisting Manager (Traction) in
discharging his duties, his main duties are as follows:
2.2.4.1 Efficient and safe upkeep and operation of the traction system, power supply installations
and SCADA system under his control in accordance with the prescribed schedules including
detailed planning of all maintenance work and also to ensure that proper maintenance records
are maintained on the formats.
2.2.4.2 Monitoring of performance of various make of equipment for further follow up measures to
improve the reliability and achieve economy.
2.2.4.3 Ensure that Traction Power controller (TPC) takes prompt and effective action to restore
services in the event of power supply interruptions or other failures of the power supply
distribution/control network affecting train services
2.2.4.4 Close liaison with power supply authorities to ensure continuity of power supply.
2.2.4.5 In-depth investigation of all the re-occurring type or major power supply interruptions &
equipment failures and taking immediate remedial measures so as to prevent.
2.2.4.6 Personal and regular checking of breakdown organization to ensure that it is in good fettle
condition to deal with all type of breakdowns & exigencies.
2.2.4.7 Prompt implementation in true spirit the instructions received from time to time including
those contained in inspection notes of superior officers and keeping record of the action taken
against each of the item.
2.2.4.8 Careful scrutiny of statistical and other periodical returns before submission to Manager
(Traction) and taking appropriate corrective action.
2.2.4.9 Effective co-ordination with officers and staff of other departments in matters that warrant
joint action and similar co-ordination with the officials of contiguous sections.
2.2.4.10 Analysis of failure reports and statements generated through SCADA system and using the
information for betterment.
2.2.4.11 Inspections of assets/installations of his jurisdiction are as under:
a) Detailed scheduled, minimum once in three months inspection of all the assets including
equipment in GSS, TSS, ASS, SCADA system and Third Rail system.
b) Frequent surprise inspections/checks of maintenance gangs at work including the working at

night.

c) Random checks of the procedures being followed for imposition of power blocks/shutdowns
and also verify that the safety procedures are being adhered to strictly.
d) Periodic inspection of sub-ordinate offices, including stores, maintenance records etc.

covering all the installations at least once in six months.
2.2.4.12 Direct control and monitoring of performance of the sub-ordinate staff like SSE/SE (Traction),
Skilled/Semi-skilled and helper staff, including their establishment/welfare matters.

3.0 SAFETY
Safety First – Always!
3.1 SAFETY INFORMATION
3.1.1 HEALTH AND SAFETY
 Fully comply with the legally recognized standards (IEC or local). The connection
conditions of the local electrical utility and the applicable safety at work regulations.
 Observe the relevant information in the instruction manual for all actions.
 Pay special attention to the hazard notes in the instruction manual marked with this
warning symbol.
 Make sure that the specified data are not exceeded under switchgear or switchboard
operating conditions.
 Keep the instruction manual accessible to all personnel involved in installation, operation
and maintenance.
Always follow the instruction manual and respect the rules of good engineering
practice!
Hazardous voltage can cause electrical shocks and burns.
Disconnect power, then earth and short circuit before proceeding with any work on
this equipment.

3.1.2 Voltages capable of causing death are used in the equipment. Personnel working near or with the
equipments should be familiar with modern methods of resuscitation. All relevant safety
precautions should be strictly adhered to during installation, commissioning, operation, testing
and maintenance of the equipments.
3.1.3 Operation of the equipments will be in accordance with this manual, taking particular account of
the safety requirements. If operators are not familiar and/or confident with the equipment, this
manual and any relevant user procedures should be reviewed. Only suitably authorized personnel
should operate the equipments.
3.1.4 PRECAUTIONS FOR SAFETY
Items to be observed to prevent physical damage or property damage and to ensure safe use of
the equipments are noted on the product and in this instruction manual.
● Please read this instruction manual and enclosed documents before starting operation to ensure
correct usage. Thoroughly understand the device, safety information and precautions before
starting operation. After reading, always store this manual where it can be accessed easily.
● The safety precautions are ranked as "DANGER" and "CAUTION" in this manual.
! DANGER: When a dangerous situation may occur if handling is mistaken leading to fatal or
major injuries.
CAUTION: When a dangerous situation may occur if handling is mistaken leading to medium or
minor injuries, or physical damage.
Note that some items described as CAUTION may lead to major results depending on the
situation. In any case, important information that must be observed is described.
● This manual is written on the premise that the user has an understanding of the operation &
maintenance and inspection of the equipments must be done by a qualified person.
Even qualified persons must undergo periodic training. The user will determine the level of
training required for the operatives in accordance with the work each will undertake.

3.1.5 Qualified refers to satisfying the following conditions.
a) The person has thoroughly read and understood the manuals.
b) The person is well versed in the installation, operation, maintenance and inspection of the
products, and understands the possible dangers.
c) The person has been trained on the maintenance, inspection and repairs of the products.
d) The person has been trained on protective tools used to ensure safety.
e) He is in possession of a valid competency certificate issued by a nominated competent

authority.

CHAPTER – II

1.0 RECEIVING SUBSTATIONS

1.1 General
RSS Types
The Phase-I network of Bangalore Metro Rail has four Receiving Substations. Out of these four
RSSs, three viz. Baiyappanahalli, Peenya and Puttenhalli are Air Insulated Switchgear (AIS) type
while the fourth i.e. Mysore Road RSS is Gas Insulated Switchgear (GIS) type.
1.2 RSS Scheme
1.2.1 The Electrical energy is fed from Power Supply Authority grid at the nominated receiving sub
stations. The power is provided at 66 kV level. The system consists of 4 RSSs at east, west, north
and south areas.
1.2.2 Each RSS has two incoming 66kV bays, two outgoing 66kV transformer bays and one bus
coupling bay. Each RSS has two 66kV/33kV Power Transformers. The power from transformers is
fed to 33kV main substation having 33kV switchgears for distributing power further to auxiliary
and traction networks.
1.2.3 The RSS receives the power from the Grid Substation through two sets of cable feeders of 630
Sq. mm Aluminium laid in ground in Trefoil formation. 66 kV substations are AIS, while 33 kV is
indoor metal clad switchgear. The RSS has one indoor TSS (750 V dc) substation to cater to the
Traction load of Depot area.
1.2.4 Two feeders are installed at each RSS with 100% redundancy for the system. Each feeder is
capable of feeding the entire load of RSS and coupling switchgear is provided at the incoming
level to facilitate the power transfer from one cable to the other. One feeder in each RSS location
serves the system, whereas another feeder is kept as hot standby.
1.2.5 The substation is a single Bus system with the sectionlizer dividing the Bus into two sections.
Each section feeding 66/33, 20/25 MVA Power Transformer which caters to both Auxiliary &
Traction loads. The 33 kV side neutral is connected to Earth through NGR to restrict the earth
fault current to 1000 Amp. Transformers are provided with OLTC for regulating the secondary
voltage.
1.2.6 Only one NGR is in operation during normal service. During normal operation, i.e. with One
Transformer in service & the other in hot standby, the NGR is kept open. During parallel
operation of the power transformer the NGR is closed.

1.3 RSS Layout
1.3.1 The 66 kV bays contain:
a) Two incoming sections
b) One bus coupling section
c) Two outgoing sections
1.3.2 Incoming Section
Each incoming section consists of:
a) One lightning arrester in each of the three phases
b) One earthing isolator to earth in the incoming cable
c) Two voltage transformer in each of the 3-phases
d) One triple pole line isolator
e) One triple pole incoming circuit breaker
f) Two current transformer in each of the three phases
g) One triple pole isolator
1.3.3 Outgoing Section
Each outgoing section consists of:
a) One triple pole isolator
b) One triple pole circuit breaker
c) One current transformer in each of the three phases
d) One lightning arrester in each of the three phases
1.3.4 Coupling and Busbar Section
The three phase busbar section consists of:
a) One triple pole circuit breaker
b) Two triple pole isolators
c) Two nos. three phase current transformer
d) Two nos. three phase voltage transformers

1.4 RSS Operation Logic
1.4.1 Charging:
Initial Charging: - Before charging the substation, it is essential that ---
a) Charging has been notified
b) Busbars are meggered.
c) DC supplies on protections are in service.
d) Necessary approvals have been obtained from statutory agencies.
e) Relay settings have been done as per the scheme.
f) Interlocks have been checked and ready for charging.
1.4.2 Keep the Isolator HIIS-1 and HIIS-2 open. Earth switch of HIES-1 and HIES-2 are
open. Charge the 66 kV feeder cable one at a time from GSS end. For example, In
case of Baiyappanahalli, the 66 kV feeders have to be charged one at a time from
the HAL/HOODY end. Observe the voltage for any abnormality.
1.4.3 Ensure all the Circuit breakers HICB-1, HICB-2, HOCB-1 and HOCB-2 are open.
Similarly, 33 kV circuit breakers LBCB-1 and LBCB-2 are open and the Earthing
isolator of these feeders are open.
1.4.4 Close Isolators HIIS-1 and HIIS-2. Also close circuit breakers HICB-1 and HICB-2
keeping HCCB open. The two sections of the Bus charged from Feeder 1/ Feeder 2.
1.4.5 Close HOIS-1 and HOCB-1 to charge the Power Transformer 1. Similarly, close HOIS-
2 and HOCB-2 to charge the Power Transformer-2.
1.4.6 Transformer should be charged one at a time preferably with time interval between
charging of the other Transformer to avoid inrush current, leading to undesired
tripping.
1.4.7 In 66 kV switchyard, a Bus coupler is provided between two sections of bus to

enhance selectivity and availability of power. By closing the Bus coupler the two
sections of the bus can be coupled.
1.4.8 Normally each 66 kV feeder feeds one section of the bus with the Bus coupler open.
In case of any fault in the service feeder, or if it is desired to take one of the feeder
for maintenance, the Bus coupler can be closed for coupling of the two buses and
one incoming feeder can feed the load of entire RSS.

1.4.9 Changeover:
1.4.10 For 66 KV switchgear at RSSs, there is a provision for transfer of power from one
feeder cable to the other feeder in case of failure of power. This transfer of power
takes through an automatic device called Line Throw Over (LTO).
1.4.11 Line Throw Over (LTO)
A line throw over (LTO) is installed for the incoming 66kV feeders in control and
monitoring panel. In case the energizing feeder is out of service, the LTO
automatically transfers from infected line to the healthy standby line within a certain
setting time delay.
1.4.12 Bus Throw Over (BTO) & Circuit Throw Over (CTO)
1.4.13 In the normal feeding scenario, one of the 66/33 kV power transformer feeds the
line load while the other is in hot standby. Therefore ―2-out-of-3‖ interlocking among
JA03, JA07 and JA10 is applicable in the normal scenario.
1.4.14 Inside each RSS, the BTO at 33kV level is provided. In case of a transformer fault or
any other failure that causes no power at 33kV switchgear incoming bay, then the
related protection relay trips out (FA04 or FA05 and JA03 or JA10 for transformer
bays), then the power will be switched-on by the BTO by automatic closing the JA07
(2 out-of-3 configuration).
1.4.15 Then both busbar and the connected loads is fed by a healthy transformer bay. The
BTO will block the Circuit Throw Over (CTO) installed at Kempegowda TSS to avoid
overload of a transformer on that RSS.
1.4.16 However, the CTO gets activated again if the BTO is released in case of faulty or
outage on a remaining transformer bay in that RSS. In this case (equivalent to
outage of one RSS of a line), both the transformers of another RSS of that line will
cater to supply of the line, thus, they will be operating in parallel and ―2-out-of-3‖
interlocking and BTO will be superseded.

1.5 66 kV FEEDERS & RSS PROTECTIONS
1.5.1 The various protections for RSSs are divided into the following:
a) High voltage (incomer and busbar) protection
b) Power transformer protection
1.5.2 High Voltage (66 kV) Protections
Incomer Line Protection:
1.5.2.1 Line Differential Protection (Pilot Wire Protection 87C)
The cable differential protection is the primary protection for the 66 kV incomer feeder
cables.
1.5.2.2 Backup Distance Protection (21)
The distance protection has characteristics that gives load encroachment discrimination
and load current compensation of the reactance line in the first zone to avoid over
reach.
1.5.2.3 Backup Overcurrent Protection (50/51, 50N/51N)
Over current tripping operates with selectable characteristics such as definite time
inverse, very inverse, extremely inverse and long-time of the four inverse definite
minimum time (IDMT) type characteristics. The current and time setting are variable
continuously over the range.
1.5.2.4 Undervoltage Protection (27)
The incomers are provided with undervoltage relay (27) to trip the circuit breakers in
case of no voltage or low voltage.
Bus Bar Protection:
1.5.2.5 Differential Protection (87B)
It has the following features:
a) Bus bar protection for each busbar has a main protection and check feature;
b) Each bus bar protection scheme operates selectively for each bus bar. It gives hundred
percent security up to 40 kA fault level;
c) Continuous supervision for CT secondary against any possibility of open circuit and if this
occurs, renders the relevant zone of protection inoperative and initiates an alarm;
d) Does not give false operation during normal load flow in bus bars;

e) Provides independent zones of protection;
f) Includes individual high speed electrically reset tripping relays for each feeder;
g) Transient free in operation;
h) Includes continuous D.C. supplies supervision;
i) Does not cause tripping for the differential current below the load current of heaviest
loaded feeder;
j) LED for relay serviceability.

1.5.3 Transformer Protection

1.5.3.1 The power transformer is provided with various main protections.
a) Differential protection (87T)
b) Restricted earth fault protection (64R)
c) Standby earth fault protection (51NS)
d) Backup O/C protection

e) Transformer Tank Protection
1.5.3.2 Apart from the above main protections, certain other protections also exist in the
system. Activation of these protections will also lead to tripping of circuit breakers.
These protections include:
1.5.3.3 Buchholz Alarm & Trip (80)
The relay is sensitive to all types of faults inside the transformer tank which produce gas
bubbles. The relay will be of the Buchholz type or the rate of pressure rise type.
1.5.3.4 Over Temperature Relay (26)
The transformer is equipped with thermal image and dial thermometer with contacts
that sound an alarm at excessive temperatures, and gives tripping orders above the
permissible temperatures.
1.5.3.5 Thermal Protection Relays (49 OT & 49 WT)
The protection includes detector coils embedded in the transformer cover to indicate oil
(49 OT) and winding temperature (49 WT) at the control board. An automatic device will
sound an alarm at failure of the cooling medium. High winding temperatures gives
tripping orders above the permissible limit.
1.5.3.6 Protection against low oil level
The transformers are equipped with devices, which sound an alarm when the oil level
drops below permissible limits.

1.6 Metering at 66 kV Level:
1.6.1 The following metering arrangements are provided on the incoming feeders from
KPTCL:
a) Ammeters (to read the value of current in each phase of each of the incoming feeders)
b) Voltmeter (to read the value of line voltages R-Y, Y-B, B-R, in each of the incoming
feeders)
c) Energy meter (Electronic energy meter, to enable measurement of Active energy (kWh),
Reactive energy (kVARh), apparent energy (kVAh), phase angle, frequency, power
factor, instantaneous maximum demand, integrated maximum demand etc. The meter
has recording and memory facilities.
1.6.2 The energy meter is trivector type having Availability Based Tariff (ABT) feature and
data ports.

2.0 RSS EQUIPMENTS

The Receiving Sub-Station includes the following equipments:
i. 66/33 kV Power Transformer
ii. 66 kV SF6 Circuit Breaker
iii. 66 kV Isolator
iv. 66 kV Current Transformers
v. 66 kV Potential Transformers
vi. Lightning Arrestors
vii. Neutral Grounding Resistor
The Guaranteed Technical Parameters of the individual RSS equipments, their operation
mechanisms and maintenance schedules for Bangalore Metro Rail – Phase I Corridor are
provided below:

2.1 66/33 KV POWER TRANSFORMER

2.1.1 Technical Specifications
The Technical Parameters are provided in Table 2.1.1 below:
Table 2.1.1 : 66/33 KV Power Transformer Technical Parameters
SN Description Unit Values
A GENERAL
1 Manufacturer ABB Ltd.
2 Place of manufacture Vadodara, India
3 Port of embarkation Vadodara, India
4 Manufacturer drawing reference 1LIN600100 –ACU
5 Standards 1EC 60076
B ELECTRICAL CHARACTERISTICS
1 Type Outdoor
2 Coupling Dyn5
3 Rated frequency Hz 50
4 Rated secondary power MVA 20/25
5 Cooling mode ONAN/ONAF
6 Primary rated insulation voltage kV 72.5
7 Primary operating voltage kV 66
8 Rated short duration power frequency kV rms 140

withstand voltage for primary winding
9 Rated lightning impulse withstand kV peak 325

voltage for primary winding
10 Primary line ends
11 Secondary rated insulation voltage kV 36
12 Secondary rated operation voltage kV 33

under load

13 Rated short duration power frequency kV 70

withstand voltage for secondary
winding
14 Rated lightning impulse withstand kV 170

voltage for secondary winding
15 Iron losses kW 18 (Max)
16 Short-circuit voltage
a. On load tap changer on tap 1 % 13% (+/- 15% Tol.)
b. On load tap changer on median tap % 12.5% (IEC Tol.)
c. On load tap changer on highest tap % 11.5% (+/- 15% Tol.)
17 Voltage drop at secondary winding
a. Rated secondary load (ONAN mode) V 6.55 % at 0.8 pf (Approx)
b. Rated secondary load (ONAF mode) V 8.29 % at 0.8 pf (Approx)
18 Copper losses
a. 4/4 of secondary load (ONAN mode) kW 64 kW (Approx) at normal tap
b. 4/4 of secondary load (ONAF mode) kW 100 kW (Max.) at normal tap
19 Short circuit current at secondary
a. On load tap changer on tap 1 kA 3.16 (Approx)
b. On load tap changer on normal tap kA(rms) 3.28 (Approx)
c. On load tap changer on tap 16 kA(rms) 3.54 (Approx)
20 Transformation ratio
a. On load tap changer on tap 16 56.1/33
b. On load tap changer on normal tap 66/33

(tap 8)
c. On load tap changer on tap 1 72.6/33
21 Power at primary winding 25
4/4 of secondary load, power factor MVA


0.95
22 Impedance voltage % 12.5 (IEC Tol.) at 25 MVA Base
23 Duration of admissible short-circuit seconds 1
24 Efficiency (not accounting for the % 99.506 %

power drawn by the secondary)
4/4 of secondary load, power factor

0.95
25 Temperature rise at thermal

stabilization at secondary at 4/4 load
a. For copper °C 55
b. For magnetic sheets °C 55
c. For oil °C 50
C CONSTRUCTION
CHARACTERISTICS
1 Winding type Continuous Disc
2 On load tap changer type High speed resistor type
a. Rating 123 kV, 250 A
b. Number of taps 16
c. Voltage corresponding to each tap 1100 V
3 Cooling system ONAF (Oil Natural Air Forced)
a. Number and type of fans 6 main + 2 standby. Axial flow type
b. Rated voltage AC V 415 V, 3 ph, 50 Hz, 4 wire
c. Fan rotating speed rpm 700
d. Power per fan kW 0.24 (Approx)
e. Fan starting current A As per fan manufacturer‘s standard

practice
f. Total power drawn by cooling kW 1.5 kW (Max)

equipment

g. Air output per fan m3/h 7900 (Approx)
h. Total air necessary m3/h 47400 (Approx)
D DIMENSIONAL
CHARACTERISTICS
1 Transformer
2 Overall dimension in cubicle
-Length mm 6800 (Approx)
-Width mm 4850 (Approx)
-Height mm 5700 (Approx)
3 Weight
-of transformer in operating condition kg 555000 (Approx)
-of oil kg 12600 (Approx)
-de tanked weight kg 31300 (Approx)
4 Rolling tracks (between inner faces of

the rails)
spacing
-large axis
m 1.676
-small axis
m 1.676
5 Preserver
Dimensions
-Oil weight kg 800 (Approx)
-Installation height mm 4500 from rail level (Approx)
6 Main parcel

7 Dimensions :
-Length/Width/Height mm 6000/2400/3900 (Approx)
weight
-with oil kg 47000 (Approx)
-with inert gas kg 37500 (Approx)
8 Handling, i.e. under hooks height

required for travelling crane to enable
handling Lifting of completely assembled
transformer is not applicable for
-Complete transformer Mm power transformers.
5200 (Approx)
9 Overall dimension drawing number 1LIN600100 - ACU
E NOISE LEVEL
1 Transformer alone (per testing mode dBA 70

stipulated in IEC standards)
2 Overall noise level
-at rated voltage and no load dBA 70
-at 110% of rated voltage and no load dBA 78
-at maximum over-induction dBA 78
F MISCELLANEOUS INFORMATION
1 Thermal time constant
-of oil h 3-4 Hours
-of transformer h 10-20 minutes
2 Maximum value of energizing current A peak 1.2 A (Approx) from HV side


at no load
3 Value of direct and reverse impedance
-as seen from primary terminals  37.72 (Approx +ve sequence

impedance)
5.5 (Approx +ve sequence

-as seen from secondary terminals  impedance)
4 Value of zero sequence impedance
-as seen from primary terminals  80 % to 105 % of +ve sequence

impedance (Approx)
80 % to 105 % of +ve sequence

-as seen from secondary terminals  impedance (Approx)
5 Degree of protection for auxiliary IP 55

circuit

2.1.2 Operation of Transformer
The Transformer has to be installed, commissioned and put into operation as per the
instructions and guidelines given in the Manual.
(Refer Manufacturer’s Manual – ABB Document No. 1LIN460022-STD)
Title: Power Transformers – Manual for Erection, Commissioning, Operation &

Maintenance
2.1.3 Energization Procedure:
Prior to energization, the transformer should be visually inspected and the following items
should be checked and executed:
Preparation for Energization
a) The oil should be filled up to the indicated level in the oil filled compartments.
b) The drying agent should be blue and the oil level in the dehydrating breather should be as
per the indication.
c) All valves must be set at the right position.
d) The transformer, the control cabinet and all accessories are cleaned and touch up painted if
needed.
e) The heating element in the control cabinet must be connected and in operation.
f) The gas-operated relay must be purged of air.
g) Any possible leakage should be checked. If the transformer has been stored more than two
months after the assembly, all sealing joints must be retightened.
h) The connections to lines, bus-bars and earth should be properly made.
i) It should be checked that the clearances between phases and phase to earth is as specified.
j) The covers have to be installed on the test taps and/or potential taps (if no potential device is
connected) of the bushings to assure proper grounding of the taps.
k) All temporary protective grounds must be removed from conductors.
l) All protective and alarm circuits have to be operational and placed into service before the
transformer is energized.
m) It should be confirmed that there are no current transformer secondary open circuits.
n) The cooling controls should be set for automatic operation.
o) The control selector-switch for the on-load tap changer in the control cabinet must be set on
REMOTE position.

p) OLTC operation is ensured prior to energization of Transformer and the tap position to be
normal.
The transformer is now ready for service upon the successful conclusion of the tests and
completion of the set time.
2.1.4 Energization
2.1.4.1 The transformer should be energized in such a way that the voltage is increased
step by step up to the rated voltage.
2.1.4.2 If it is not possible to use a generator, the transformer may be connected directly to
a live transmission line at no load.
2.1.4.3 After energizing, the transformer has to be kept under careful observation for the
first 12 hours.
2.1.4.4 The following should be checked and monitored for 12 Hours:
a) Oil Temperature,
b) The Winding Temperature,
c) The Tank Pressure,
d) The Ambient Temperature
2.1.4.5 When the transformer is successively loaded, the transformer has to be observed for
a few hours, especially the temperature gauges and the gas relay.
2.1.4.6 The observation should continue on a daily schedule for seven days and then weekly
for the first month of operation.
2.1.4.7 When the transformer has been in service at normal working temperatures, all
sealing joints have to be retightened.

2.1.5 General Supervision & Maintenance
2.1.5.1 General
In order to avoid faults and disturbances, it is important that a careful and regular
supervision and control of the transformer and its components is planned and carried
out. The frequency and extent of such a supervision and control depends on climate,
environment and service conditions etc.
Note: Spare transformers are supervised and maintained according to the same
schedule as transformers in service.
2.1.5.2 Dirt and Dust
The external transformer surfaces should be inspected regularly; and when required
cleaned from dust, insects, leaves and other airborne dirt.
2.1.5.3 Possible Oil Leakage
After energizing, a certain setting may appear in sealing joints. They should therefore be
retightened after the transformer has been in operation for about a month and
thereupon when needed. This applies especially to sealing joints with plain gaskets that
are not placed in grooves.
2.1.5.4 Rust Damages, Touch-up Painting
A regular inspection of the external surface treatment of the transformer should be

carried out. Possible rust should be removed and the surface treatment restored to
original state by means of the primer and finish-paints that are dispatched with the
transformer.
2.1.5.5 Oil-level Indicator for Oil Conservator
The oil conservator is provided with an oil-level indicator. The correct oil-filling level is
specified on an information plate.
The indicator has alarm contacts for low and high. On alarm, the cause will be
established and measures should be taken to reach the correct oil level.
2.1.5.6 Gas in Oil Analysis
Regular gas in oil analysis is recommended. As a guiding value gas in oil analysis once a
year is recommended.
2.1.5.7 Oil Analysis
In addition to gas in oil analysis, a more or less complete chemical analysis of the oil is
recommended.
2.1.5.8 There are two types of Tests:

a) The small test covers:-
− Color
− Visual inspection
− Moisture content
− Dielectric breakdown withstand
− Neutralization number
b) The large test covers four more tests in addition to the above:
− Inhibitor content established (GC-method)
− Power factor, tan delta, depending on the situation
− Interfacial tension
− PCB Content
2.1.5.9 These tests are in addition to the conventional gas in oil analysis. Such tests are
recommended when gas in oil analysis has given indication of non-conformance of
the transformer.
As a guiding value, oil analysis should be done about once every year if not
otherwise necessary depending on the outcome of other tests.
2.1.5.10 Moisture
Some build-up of water content is inevitable, due to the aging processes. The oil
may also have been subjected to moist air. The moisture content and the dielectric
withstands of the oil will be checked as part of the small and large test or whenever
there is a suspicion that oil has been exposed to humidity.
2.1.5.11 Sludge, Acid
The transformers and reactors are filled with inhibited oil. The inhibitor works as an
antioxidant (a preserving agent). When the oil is aging, sludge and acid products
develop. The inhibitor retards the ageing process and extends the utilization time of
the oil.
2.1.5.12 When this occurs the oil will be analyzed and the neutralization number and the
remaining inhibitor content will be determined. The oil should be replaced or
regenerated, if the neutralization number is larger than 0.1 to 0.15 mg potassium
hydro oxide (KOH) per gram oil in inhibited oil, (alternatively larger than 0,2 mg
KOH/g in non-inhibited oil) and/or an inhibitor content less than 0,1%.
Larger values on neutralization number or less inhibitor content than stated here will
accelerate the ageing.

2.1.5.13 The exchange of oil should be as complete as possible, because old oil will infect the
new one and thus speed up the ageing process. The exchange should preferably be
carried out when the oil is warm and the oil viscosity is low. In inhibited oil where
only the inhibitor content has decreased the addition of new inhibitor is a possible
option.
2.1.5.14 Temperature Supervision
It is important to keep the oil and winding temperatures under continuous

observation. The temperatures should be read regularly and the measured values
registered. These values will give guidance for judging of the service life of the
transformer, cooling system functions etc.
2.1.5.15 Overload
The transformer can normally be overloaded at low ambient temperatures. However,

the permissible overload must not be judged only with regard to the oil temperature.
The winding absolute temperature has to be considered together with permissible
current loading of accessories like bushings and tap-changer.
If the temperature in a transformer shows a tendency to rise without a

corresponding increase of the load, there may be a reduction of the ability of the
cooling equipment due to dirt and dust. However, the thermometers should be
checked first.
2.1.5.16 Winding Temperature Indicator
The thermometer system has a sensor, temperature signal transmission and display
system similar to the oil thermometer. The measured oil temperature is "adjusted"
by a temperature increase corresponding to the temperature difference between the
oil and the winding conductor.
2.1.5.17 This temperature increase is obtained by a heating element carrying a current

proportional to the winding current. A separate current transformer in the winding
circuit will provide the current. An adjustable shunt resistor in the current
transformer heating element circuit facilitates the calibration of the thermometer to
display a correct winding temperature. The calibration is normally based on the
outcome of a heat run test. The heating element and the shunt element may be
located in the display instrument or at the sensor body in the thermometer pocket.

2.1.6 Maintenance Schedule
Table 2.1.2: Maintenance Schedule
Equipment Power Transformer
Make: M/s ABB Limited
System Voltage 66/33 KV
Schedule Sl. No Check List
1 Checking of bushing oil level
2 Checking of oil level in Conservator
3 Cleaning of all Bushings with dry clothes.
4 Cleaning of transformer and its other accessories.
5 Check whether there is any leakage of oil, If required rectify.
6 Check oil level in conservator tank, if it is below 1/4 level oil should
be topped up.
7 Checking of oil level in OLTC Conservator
8 Checking condition of Silica gel in breather and re-condition if

Monthly
required
Maintenance
9 Check electrical connections for its tightness if found loose
tightened the same.
10 Checking/Topping up of oil level in oil seal of breather
11 Record maximum oil & winding temperature in a register.
12 Cleaning of Marshalling boxes.
13 External cleaning of Radiators and other parts of transformer.
14 Tightening of terminals.
15 Check Pressure relief device for any damage.

16 Checking of contactors, space heaters, illumination etc.
17 Check all earth connections of transformer and tank CT.
18 Check if there is any abnormal sound from transformer while

energized.
19 Check name and danger board
20 Check for gas collection in Buchholz relay
21 Clean tap changer box and tighten all electrical connections.
22 Check all the cable entry for the protection equipments are properly
sealed.
1 All checks from monthly schedules
2 Checking of oil level in WTI and OTI pockets
3 Check operation of tap changer.
4 Test oil sample from tank bottom for crackle test, acidity and BDV.
Oil sample should be taken during day time in good weather. If
BDV is less than 50 KV, oil should be filtered.
5 Measure and record insulation resistance of all windings to earth &

primary winding to secondary.
HV + E=2000 M ohms, LV + E =400 M ohms. HV + LV = 2500 M

ohms. by 2.5KV/5.0KV - Megger
Half-Yearly
Maintenance
6 Check all alarms and trip circuits for proper functioning such as
buchholz relay, pressure relief device, OLTC surge relay etc...
7 Check all SCADA signals.
8 Measure IR value of tank and WTI CT and winding continuity.
9 Check and measure tap changer motor winding resistance.
10 Check of current carrying contacts preferably by a thermo vision

camera while the transformer is in service. Retighten them if
required as per torque specified in the instruction manual

1 All checks from half yearly maintenance schedules.
2 Calibration of OTI, WTI meter. OTI Alarm : 80 deg C, Trip: 90 deg

C, WTI Alarm : 85 deg C, Trip: 95 deg C
3 Collect oil sample in dry and clean bottle for DGA analysis.
4 Maintenance of OLTC driving mechanism

Yearly
Maintenance 5 Calculate Polarization index , it should be more than 1.3
6 Checking/Replacement of the gaskets of the terminal box
7 Paint transformer wherever required.
8 Check voltage ratio at different tap.
9 Overhauling of transformer in every 10/12 years
Remarks: -
a) Ensure that the equipment is disconnected from all electrical supply. Earth them at both
ends before carrying out any maintenance work.
b) Always follow the instruction and Maintenance Manual of the manufacturer.
c) All safety precautions will be taken during Maintenance.
d) Standard tools and accessories as per Instruction and Maintenance Manuals will be
ensured for facilitating the normal maintenance activities on the Equipment.
e) All Drawings and Manufacture‘s Instruction & Maintenance manual will be ensured at
site for reference during Maintenance.

2.2 66 KV CIRCUIT BREAKER
2.2.1 General Description
2.2.1.1 Structure
The circuit breaker consists of three separate circuit-breaker poles, operating
mechanism and link system.
Each circuit breaker pole consists of three main components:
a) A mechanism
b) A hollow post insulator with insulating pull-rod
c) A breaking unit that consists of a breaking chamber insulator with attendant flanges
and adapter plates. The interior of the breaking unit consists of a fixed upper and
lower current path with integrated contact system and a moving puffer unit.
d) The circuit breaker poles are mounted on a pole beam. The pole beams as well as
the attendant two column support are both hot-dip galvanised. The circuit breaker
poles are linked using torsion rods.
2.2.1.2 Breaking Principle
2.2.1.2.1 The breaking unit works as per Auto-puffer principle with a puffer cylinder that is
divided into two chambers: -- One Auto Puffer section and other a Compression
section.
2.2.1.2.2 When the normal rating current is interrupted the SF6 gas is compressed in the
compression section to an overpressure. When the arcing contacts separate, the gas
in the compression section flows out and extinguishes the arc at a current zero
passage.
2.2.1.2.3 When the short-circuit current is interrupted, the requisite extinguishing pressure is
built up in the Auto-Puffer section through heating from the arc. The pressure
increase is achieved with energy from the arc and no extra energy is required from
the operating mechanism.
2.2.1.2.4 On closing, the puffer cylinder slides upwards, the contacts engage and the puffer
cylinder is refilled with gas.

The technical parameters of 66 kV SF6 Circuit Breaker is provided in Table 2.2.1

below:
Table 2.2.1: Technical Parameters of SF6 Circuit Breaker
Sl.No. Description Unit Values
1 Name of the manufacturer ABB Ltd
2 Country of manufacture India
3 Relevant Specification IEC 62271-100 & IEC 62271-1
4 Type Outdoor
Substation type AIS
5 Phase numbers 3
6 Rated frequency Hz 50Hz
7 Rated insulation voltage kV 72.5kVrms
8 Rated operating voltage kV 66kVrms
9 Rated short circuit duration power frequency kV rms 140kVrms for 1 min
withstand voltage
10 Rated lightning Impulse withstand (1.2/50 kV peak 325kVpeak

micro second)
11 Rated current A 1250Amp
12 Rated short circuit withstand current (1 sec) kA rms 40kArms
13 Rated peak withstand current kA Peak 100kApeak
14 Breaking capacity kA rms 40kArms
15 Making capacity kA Peak 100kApeak
16 Breaking mode SF6

17 Rated operating cycle CO-15‖-CO
18 Rated auxiliary voltage V dc 110VDC
19 Operating time from actuation to ms 65ms

extinguishing of primary arc
20 Rated transient recovery voltage (first pole 1.5 (first pole to clear factor)
to clear factor 1.5)
a. Test duty T10
b. Transient recovery voltage peak value kV 272
c. Time s 39
d. Time delay s 6
21 Operating times
a. Opening actuation ms 50ms
from current emission on the release coil up

to Separation of contacts (opening time)
b. Extinguishing of primary arc (breaking time ms 65ms

at rated breaking capacity)
c. Closing actuation from current emission on ms 75ms

the engagement coil up to Establishment of
current (establishment time)
d. Start of connecting (closing time) ms 75ms
e. Maximum operating difference between

poles
- At opening
ms 3.33ms
- At closing
ms 5.0ms
22 Rated SF6 pressure for operation MPa 7 bar (abs) at 20ºC

23 Rated SF6 pressure for breaking MPa 7 bar (abs) at 20ºC
24 SF6 under-pressure first threshold alarm MPa 6.2 bar (abs) at 20ºC
25 SF6 under-pressure blocking MPa Blocking provided at 6.0 bar (abs)
26 Operating system NA (we have provided spring

operated mechanism)
rated pressure MPa
minimum pressure %
maximum pressure %
27 Operating and auxiliary cubicle protection IP55

degree
28 Circuit breaker position auxiliary contact Will provide at the event of order
during detail engineering
open position make contacts
open position break contacts
closed position make contacts
- closed position break contacts

2.2.3 Operating Mechanism
The Circuit Breaker has to be installed, commissioned and put into operation as per the
instructions and guidelines given in the Manual.
(Refer Manufacturer’s Manual – Title: SF 6 Circuit Breaker – Product Manual)
2.2.3.1 The circuit breaker is operated by a motor charged spring operating mechanism.
2.2.3.2 The operating mechanism is connected to the circuit breaker poles‘ mechanism via a
transmission rod and two torsion rods.
2.2.3.3 The transmission rod runs from the switching shaft of the operating mechanism to
the mechanism of the circuit breaker pole and thereby transfers closing and opening
travel to the circuit breaker.
2.2.3.4 The circuit breaker is closed using an operating mechanism that contains a closing
spring. When closing, the trip spring is charged which is also located in the operating
mechanism.
2.2.3.5 The tripping latch in the operating mechanism keeps the circuit breaker in closed
position. For opening, only tripping of the tripping latch is required.
2.2.3.6 The circuit breakers comply with the requirements in the IEC 62271-100 standard
and are restrike free when breaking capacitive load.
The detail labelling has been shown in Fig. 2.2.1 below:

Fig. 2.2.1: Circuit Breaker Components

2.2.4 Closing & Opening Operations
2.2.4.1 Closing: When the signal indicates that the circuit breaker will close, the closing
latch is released from the main shaft and the closing spring trips. This implies that
the cam disc rotates via the closing lever. The switching shaft is put in motion and
the circuit breaker closes, at the same time as the trip spring in turn is charged and
locked.
The motor then charges the closing spring following each closing operation, via the
main shaft and worm gear. When the spring is then charged, the circuit is broken by
the limit switch.
2.2.4.2 Opening: When the signal indicates that the circuit breaker will open, the tripping
latch device releases from the switching shaft and the trip spring trips, and thereby
opens the circuit breaker.
2.2.4.3 Remote/Local Operation

For normal operation, the ―Local/Remote/Disconnected‖ switch is in the ―Remote‖
setting for electrical remote control. In the ―Local‖ setting, operation can only be
executed using the ―Close/Open‖ control switch. The ―Disconnected‖ setting is used
for maintenance.
2.2.4.4 An opening operation for a closed circuit-breaker can be done when the
―Local/Remote/Disconnected‖ switch is in the ―Local‖ setting mode and the
―Close/Open‖ control switch is set to open.
2.2.4.5 A closing operation using the ―Close/Open‖ control switch or electric remote impulse
can only be done if:
a) The ―Local/Remote/Disconnected‖ switch is in the ―Local‖ or ―Remote‖ setting.

b) The closing spring is charged.
c) The circuit-breaker is in open position.
d) The gas density is larger than the blocking level.
2.2.5 Auto-Reclosing
Auto-reclosing, ―Open-0.3 Sec-Close-Open‖ is possible if:
a) The circuit breaker is closed. (Tripping and protection type activated)

b) The ―Local/Remote/Disconnected‖ switch is in the ―Remote‖ setting.
c) The operating mechanism‘s closing spring is fully charged when the operating
cycle begins.

Table 2.2: Maintenance Schedule
Equipment 66 kV SF6 CIRCUIT BREAKER
Make: M/s ABB LIMITED
1 Remove the accumulated dust by Vacuum Cleaner. If

any part of the interior is badly rusted indicating entry
of moisture, find out the cause, plug the hole and
repainted the rusted parts.
2 Examine leading pipe connection for proper sealing
3 Check for any SF-6 Gas Leakage
4 Check if all pins and checkouts are in place
5 Check all tie rod nuts for tightness.
6 Operate the mechanism twice manually and electrically
by Remote/Local keeping the control box door open
and check for any abnormal noise.
7 Check the heater in functioning properly
8 Check interlock of the equipment.
9 Check local position indicator and remote semaphore
indicator for operation.
10 Check the electrical connections for tightness
Quarterly Maintenance
11 Checking of fasteners tightness.
12 Checking of CB for Rack In & Out
13 Tightening of cable terminations.
14 Clean the Bushing of the pole and check for any crack
and flash of bushings
15 Checking of Earth switch operation & its event in
SCADA check that good connection is made.
Re-grease the shaft.
16 Clean the bushing.
17 Checking of shock absorbers for leakage or stuck up –
position F&G
18 Check the door gaskets, replace if required.
19 Any damage cubicle surface either inside or outside
should be treated with touch up paint or protected
against rust with their layer of grease.

20 Carry out the following electrical checks

- Few closing & opening operations and check for
correct indications,
Proper operation of the motor, auxiliary circuits
- Proper operation of service limit switch after
few racking movements of
The breaker from `Test‘ to `Service‘ and vice
versa
- Proper functioning of interlocks
21 Check for any foreign material inside a breaker

1 All checks of quarterly maintenance.
2 Checking of Top & bottom trip free mechanism cap &
coupling.
3 Coupling knife catch gap -gaps should be 1-
2mm
4 Bottom TFM & Cap gap - gaps should be 1-2 mm
5 Spring cut off micro switches.
6 Spring charge time. It should be less than 15 sec.
7 Check tripping of CB on DC failure.
8 check trip of CB on over current protection
Half-Yearly Maintenance
9 Check tripping of CB on under voltage.
10 Check the resistance value of Opening & Closing Coil
Terminals for Closing coil: Measure Resistance
between 101, 102(terminals)
Terminals for tripping coil: Measure Resistance
between 103, 104(terminals)
11 Measure contact resistance of CB. <100 micro ohm

12 Check open time <45 ms, close time< 75 ms & CO
time <100 ms of CB .
1 All checks of half yearly to be done
2 IR value of CB bushing to be measured By 5 KV
megger
>1000 M ohm
3 Check all signals on SCADA
Yearly Maintenance
4 Check gas pressure low. Gas Pressure at 200 C should
be 3.5 bar abs.
5 Overhauling of CB after every 10,000 operations.
6 Overhaul and lubrication of charging device and
operating device

2.3 66 kV CURRENT TRANSFORMER
2.3.1.1 The detailed labeling and description of the Current Transformer is shown and
provided below:
Fig. 2.3.1: Current Transformer Structural Design
1. Porcelain insulator
2. Aluminium alloy coffer-dam
3. Current terminal P2
4. Current terminal P1
5. Primary diverting device
6. Bottom support
7. Secondary terminals
8. Primary circuit
9. Secondary core
10. Gas SF6 filling plug
11. Contact pressure meter
12. Entrance secondary box
13. Pressure relief device
14. Eye bolts

2.3.1.2 Description
a) An envelope made with:
 A shredded porcelain insulator (1), giving insulation between live part and earth,
housing the longitudinal part of the secondary winding;
 An aluminium alloy coffer-dam (2), housing the primary winding (8), as well as
toroidal core, the secondary winding and the pressure relief device (13);
 Current terminals (3) and (4) for connection to the external circuit;
 Bottom support (6), supporting the insulator, it has incorporated the secondary
terminals (7), the pressure meter with a.m. contacts (11) and SF6 filling (10)
 Molecular tightness of the envelopes is individually checked by means of

appropriate SF6 detector inside pressurized cells.
b) The active part consisting of:
 The primary circuit (8), made with one or more coils, connectable one to each
other with a diverting device (5), linked with toroidal zone of the secondary
winding (9) and having its ends connected to current terminals (3) e (4);
 The secondary circuit of the CT made with secondary winding around magnetic
core and its vertical earthed connection to the terminals;
 The toroidal magnetic cores, made with grain oriented steel sheets.
Cores and secondary windings are located on the top, inside the head of CT; high
voltage insulation is fully obtained with SF6 gas.
This design has several and remarkable advantages:
 The dielectric quality is neither depending on long and complex treatments nor on
delicate checks during life-time of the equipment.
 Probability of internal discharge is none as a consequence of an insulation co-

ordination of gaseous dielectric medium; furthermore the specific features of sulphur
hexafluoride are such to give very small consequences of discharges, if any.
 A device having a pre-set breakage provides the CT with a protection against

possible overpressure.
 Internal insulation can be continuously monitored by means of a pressure-gauge

fitted with alarm and trip contacts in case of gas pressure decrease.

2.3.2.1 The Guaranteed Technical parameters for 66 kV SF6 Current Transformers is

provided in Table 2.3.1 below:
Table 2.3.1: SF6 Current Transformer (66 kV) –Technical Parameters
1 Manufacturer ABB PT S.p.A
Unita Operativa ADDA
2 Place of manufacture Lodi, Italy
3 Port of embarkation Genova, Italy
4 Manufacturer drawing reference 2GJA300199
5 Standards IEC 44-1
6 Type Outdoor
7 Type of substation Open
8 Number of phases 3
9 Rated insulation voltage kV 72.5
10 Operating voltage kV 66
12 Rated short duration power frequency kV rms 140

withstand voltage

voltage
14 Insulation medium SF6
a. SF6 rated pressure MPa 400 kPa
b. SF6 minimum pressure % 330 kPa

c. SF6 maximum pressure % 1050 kPa (Rupture Disk Pressure

Release)
15 Short-circuit current allowable for 1 kA 40

seconds
16 Permanent operation without danger In 800 or 1600 A
17 Overheating In 1.2 x 800 (1600)
18 Total weight kg 180 kg per CT
19 Overall dimension of one element 780 mm x 1525 mm
20 Degree of protection for auxiliary IP 55

circuit
2.3.3 Operation Parameters
Pressure Schedule
Sl. Description TG 72 TG 145-170

No.
1 Rated Pressure Pn or Filling 4 (0.40) 6 (0.60)
Pressure Bar (MPa)
2 2nd Ceiling 3.3 ± 0.05 (0.03 ± 5.3 ± 0.05 (0.53 ±
Lock Pressure Bar (MPa) 0.005) 0.005)
3 1st Ceiling 3.5 (0.35) 5.5 (0.55)
Alarm Pressure Bar (MPa)
4 SF 6 Weight 2.7 Kg 4 Kg
5 Filling Pressure during 0.1 – 0.2 Bar 0.1 – 0.2 Bar
Transportation (0.01 – 0.02 MPa) (0.01 – 0.02 MPa)

2.3.4 Filling procedure of CT with gas --SF6
a) Fill the CT with SF6 up to the rated pressure given on the schedule
accompanying the apparatus.
b) Sulphur Hexafluoride must be 99.8% ;
c) Filling procedure must be followed according to Fig. 2.3.2
 Purge the pipe as follows:
i) It should be made sure that pressure-reducing valve is completely close (no

pressure at the output) and that pipe fitting is not connected.
ii) Open the valve (1) partially and the valve (3) completely,
iii) Allow the gas SF6 to come out under reduced pressure by the valve (2) - 0.2/0.3
bar- for 5 sec. each 3 meters pipe-length and keep the pipe upwards;
iv) Quickly connect the pipe (4) with pipe fitting to the filling plug (6) on CT bottom
and allow gas to come out;
v) Open the valve (1) completely (the manometer A will show about 20 bar),
consequently increase gradually the opening of the valve (2) by several steps of
about 1 bar, up to the achieving of the rated pressure Pn on the manometer B;
vi) Read the pressure by manometer fitted on the base of CT and close valves (3)
and (1) as soon as the rated pressure Pn is reached.

Fig. 2.3.2: SF6 Gas Filling Procedure
d) The pressure must be finally adjusted to its correct value.
e) This operation has to be performed after the temperature of the quantity of gas
introduced is stabilized that is to say after 12 hours from the filling in operation.
f) The value of the correct pressure has to appear on its schedule in order to make
the checks easier.

a) No periodical check is necessary.
b) Monitoring of pressure can be done from remote control room continuously, by

means of contact pressure meter.
c) After long time from installation, especially in dusty or coast areas, some deposits on
the insulator could produce a certain surface conductivity.
Washing of insulator is then advisable. Periodical cleanings depend on the

environmental conditions.
The CT transformers are completely tight, so it is possible to clean insulators using

high pressure water pump without risk of damage.

Equipment 66 kV SF6 CURRENT TRANSFORMER
Make: M/s ABB Limited, Italy
Type TG 72-145-170
1 Check and clean the CT porcelain insulator for its

cleanliness.
2 Check and tighten terminals nut and bolts.
3 Check and tighten the secondary terminals.
4
Monitor the SF6 pressure from control panel as well
as from the local gauge and record the readings.
5 If any SF6 alarm comes, top up with SF6 gas as per

the instruction manual.
6 Check the gasket for its wear and tear and replace
even at slight damage.
1 All checks from half yearly schedule
Yearly Maintenance
2 Measure insulation resistance.

Remarks: -
1. Ensure that the equipment is disconnected from all electrical supply. Earth them at
both ends before carrying out any maintenance work.
2. Manufactures Instruction & Maintenance Manual shall be referred during
Maintenance.
3. All safety precautions shall be ensured during maintenance.
4. All PPE‘s (Personal Protective Equipment) shall be ensured at site during
maintenance.

2.4 66 kV POTENTIAL TRANSFORMER

2.4.1 GENERAL DESCRIPTION
Fig. 2.4.1: General Arrangement of 66 kV Potential Transformer

2.4.1.1 The outdoor oil filled Voltage Transformer (VT) consists of the following:
1. Bottom tank with mounting Channel and Integral Secondary terminal Box.
2. Main Porcelain Bushing mounted on Bottom tank.
3. Oil Expansion chamber fitted with oil level indicator and pressure release diaphragm,
mounted on bushing.
2.4.1.2 The Voltage transformer bottom tank is fabricated from mild steel plates. It houses
the core and coil assembly. Secondary Terminal Box forms an integral part of tank.
2.4.1.3 The box is provided with suitable cable entry at the bottom. Neutral point of primary
winding is brought out through a suitable insulated terminal in a separate earthing
box and provided with shorting links to keep neutral terminal shorted to earth in
normal operating condition of VT.
2.4.1.4 The High Voltage lead of voltage transformer is taken out through porcelain bushing
mounted on bottom tank and is terminated at top chamber where a primary terminal
is provided to connect the voltage transformer to external line.
2.4.1.5 The top chamber, which acts as Oil Expansion Chamber is fitted with oil level
indicator, Pressure Release Diaphragm, Oil filling plug and Nitrogen filling valve.
2.4.1.6 A Dome Shape Cover is provided to protect the pressure diaphragm and nitrogen
filling valve from rainwater.
Note: The Voltage Transformer after careful drying is filled with High Quality de-aerated
oil under vacuum.
To seal it, the space left for expansion on the top is filled with dry and pure Nitrogen
through non-returnable valve at predetermined pressure.
It is important that the Voltage Transformer is always kept in a vertical position so that
the gas forming a cushion at the top remains at top only.

The guaranteed technical parameters of 66 kV Potential Transformers is provided

in Table 2.4.1 below:
Table 2.4.1: Technical Parameters of 66 kV Potential Transformers
1 Name of the Manufacturer M/s Vishal Transformers &

Switchgears (P) Ltd, Meerut
2 Country Of Origin India
3 Manufacturer‘s Type and Designation VISHAL make, Outdoor Oil cooled
4 Standards Applicable IS:2705
5 Type of Installation Outdoor
6 Mounting of Tank (Bottom) Bottom
7 Rated Primary Voltage kV 66 kV/ √3
8 Secondary Winding Details
(i) No. of Secondary Winding Two
(ii) Rated Secondary Voltage V
Winding – I 110 V/√3
Winding -- II 110 V/√3
(iii) Rated Burden VA

Winding – I
Winding -- II 10 VA
10 VA
(iv) Class of Accuracy
Winding – I 0.2
Winding -- II 0.2

9 Maximum Ratio Error with % rated As per IS

burden and 5 % normal primary
voltage
10 Temperature Rise at 1.1 times rated Deg C 45

voltage with rated burden
11 Rated Voltage factor and time 1.2 Continuous
12 Impulse Withstand test voltage kV 325

(Peak)
13 One minute power frequency kV (rms) 140

withstand test voltage on primary
14 One minute power frequency 3

withstand test voltage on secondary
15 Total Creepage distance of the bushing mm 1825
16 Sealing (Metal Bellow) provided Provided
17 Quantity of insulating oil Litres 55 +/-5
18 Total weight including oil Kg 220 +/- 20

2.4.3 FILLING PROCEDURE OF PT WITH GAS -- NITROGEN:
a) Remove the oil filling plug.

b) Start filling Nitrogen gas through Nitrogen value with very low pressure by regulating
pressure with pressure regulator provided on the Nitrogen Gas Bottle.
c) The Nitrogen should be kept flowing at least for 5 minutes.
d) Nitrogen will slowly settle down at bottom, pushing air upward through oil filling plug.
e) After 5 minutes, close the oil filling plug with rubber ‗O‘ ring and cap.
f) Fill Nitrogen up to 5 psi pressure (approx. 0.30Kg/cm2). Check whether valve is leaking.
g) The pressure inside the tank may be checked for confirmation after 24 hours for any
leakage.
2.4.3.1 Nitrogen can also be filled by following procedure:
a) Fill the oil in the tank up to the top plate so that no air remains in the tank.
b) Close the oil-filling plug.
c) Open the oil drain plug and start filling Nitrogen from valve provided on the top plate
of the tank simultaneously.
d) Close the oil Drain Plug when oil level drops to minimum level (Normally half level in
oil level indicator). Fill Nitrogen up to 5-psi pressure (approx.0.30Kg/cm2).
Note: This method of Nitrogen filling is most effective than the one mentioned earlier.
However, it may be little difficult to close the oil drain plug as oil is drained with higher
pressure.
2.4.4 OIL FILTRATION:
2.4.4.1 If the insulation resistance of the Voltage Transformer is low, it can be improved by
oil filtration under vacuum.
The procedure for oil filtration is as follows:
a. Remove the Nitrogen valve and connect suitable adaptor to connect incoming
oil pipe of the filtration machine.
b. Remove oil drain plug and connect other oil-outgoing pipe of oil filtration machine to
it.

c. Start the filtration machine and keep it running for at least 36 to 48 hours (It is
always better to keep filtration for more than 36 hours, as it takes times to transmit the
heat inside the insulation and remove the moisture).
d. After filtration, close the drain Plug and Nitrogen valve and fill the Nitrogen as
explained above.
2.4.5.1 All Voltage Transformers are of ―Sealed Type‖ construction and do not require any
maintenance, except occasional cleaning of Bushing.
However, following checks are for trouble-free continuous operation:-
a) Check the IR value of each VT periodically preferably once in six months and keep
record. If the IR values indicate decreasing trend, check Nitrogen Pressure. Nitrogen
may leak through defective/damaged diaphragm.
Due to this there is always a possibility of moisture entering the oil tank through the
leaking part, resulting in contamination of oil and subsequently lowering the IR
values.
If such Voltage Transformer is kept in service, it may explode. The IR value also
decreases due to ageing effect.
However, the rate of fall of IR value with respect to period, due to ageing is less
than that due to moisture ingress.
b) As primary winding is provided with graded insulation and neutral point is brought
out through a 3 kV Bushing. IR value of primary will be low unlike Current
Transformer.
If IR of primary to earth and secondary to earth both show very low value and
nitrogen pressure is not present in VT, It is advisable to test oil sample taken from
VT to confirm the healthiness of VT.
c) Check the Pressure Diaphragm as per procedure explained in the Commissioning

Manual. If pressure diaphragm is defective, replace it with new one.
Following is the procedure for replacing diaphragm:-
i) Remove the flange by removing six nuts, provided along the periphery of the flange.
ii) Remove the Pressure Diaphragm.
iii) Remove rubber ‗O‘ ring.
iv) Put new rubber ‗O‘ Ring (Old Rubber ‗O‘ Ring may be used if it is not defective).

v) Clean the surface of both flanges .Places the Diaphragm on the rubber ‗O‘ ring such
that Hylum sheet exposes to the atmosphere. Place other flange over it and tighten the
nuts.

Equipment 66 kV POTENTIAL TRANSFORMER
Make: M/s Vishal Transformers & Switchgears (P)

Ltd
1 Check and clean the porcelain insulator for its

cleanliness.
3
Check and tighten the secondary terminals.
4 Check the earthing connection of the tank.
5
Check for any leakages.
Check secondary bushings for leakages. If minor
Quarterly Maintenance leak is there rectify it.
Do not over tighten the nuts. Refer manuals.
6
Check the gasket for its wear and tear and replace
even at slight damage.
7
Check the CVT fuses and replace if found faulty,
replace them with proper rating.
8
Check the oil level
1
All checks from half yearly schedule
2
Measure insulation resistance.
3
Measure secondary winding resistances.
Refer test reports.

Remarks: -
1. Ensure that the equipment is disconnected from all electrical supply. Earth them at both
2. Manufactures Instruction & Maintenance Manual shall be referred during Maintenance.
4. All PPE‘s (Personal Protective Equipment) shall be ensured at site during maintenance.

2.5 ISOLATOR

2.5.1.1 Isolator comprises of three identical single pole units consisting of:
 A galvanized rigid base made of distortion resistant structural steel having fixing
arrangements to the supporting structure by means of drilling holes and also
having two elevator plate/channels on both sides and a rotating bearing unit with
interconnecting pipe (tandem pipe) fixing clamps. (Refer part Drg ―A‖)
 3 Nos. porcelain insulator stacks. (Refer part Drg ―B‖)
 2 Nos. fixed contact assemblies with arcing horns for mounting on side insulator
stacks. (Refer part Drg ―C‖)
 1 No. moving contact assembly with arcing horns (Refer part Drg ―D‖) for
mounting on centre insulator stack.
 Top operating mechanism for isolator (Refer part Drg ―E‖) or rotating bearing
units with interconnecting pipe clamps and top operating mechanism. (Refer part
Drg ―F‖)
 Operating Mechanism (Motor/Manual) (Refer part Drg ―G‖)
 Group operating pipe (Tandem pipe) for interconnecting three poles (Refer part
Drg ―H‖)
 Operating Pipe (Down pipe) for interconnecting the top operating mechanism
and operating mechanism (Motor/Manual) (Refer part Drg ―I‖)
2.5.1.2 Earth Switch also comprises of three identical single pole units consisting of:
 Moving contact fixing assemblies with inter connecting pipe fixing clamps and
interlock pipe with link assembly (Refer part Drg ―J‖) fitted to base.
 1 No. fixed contact assembly fitted to the isolator fixed contact (Refer part Drg
―K‖)
 1 No. moving contact assembly fitted with flexible (Refer part Drg ―L‖)
 1 No. top operating mechanism (Refer part Drg ―M‖)
 Operating mechanism for earth switch (Motor/Manual) (Refer part Drg ―G‖)

 Group operating pipe (Tandem Pipe) for interconnecting earth switches (Refer
part Drg ―H‖)
 Operating pipe (Down Pipe) for interconnecting the top operating mechanism
and operating mechanism (Motor/Manual) (Refer part Drg ―I‖)
 Auxiliary coupler pipe which connects the earth switch inter connecting pipe with
top operating mechanism (Refer part Drg ―N‖)
Fig 2.5.1: General Arrangement of 66 kV Isolator

Fig 2.5.2: General Arrangement

Fig 2.5.3: General Arrangement of Operating Mechanism

Fig 2.5.4: General Arrangement

Fig 2.5.5: Mounting Arrangements


The technical parameters of 66 kV Isolator are provided in Table 2.5.1 below:
Table 2.5.1: Technical Specifications
1 Name of the manufacturer GR Power Switchgears Limited
2 Country of manufacture Hyderabad, India
3 Port of embarkation NA
4 Manufacturer drawing reference ―DB‖ Double Break
5 Relevant Standards IS 9921 Part I to V/ IEC 694, 129
6 Type Outdoor
7 Substation type Open
8 Phase numbers Three
9 Two rotating columns Centre Post Rotating Double Break

―DB‖
10 Rated frequency Hz 50 Hz
11 Rated insulation voltage kV 72.5 kV
12 Rated operating voltage kV 66 kV
13 Rated short circuit duration power kV rms 140 kV rms

frequency withstand voltage
14 Rated lightning Impulse withstand kV peak 325 kV peak

(1.2/50 micro second)
15 Rated short duration power frequency kV rms 160 kV rms

withstand voltage across isolating
distance
16 Rated lightning impulse withstand kV peak 375 kV peak

voltage across isolating distance

17 Rated current A 1000 Amps
18 Rated short circuit withstand current (1 kA rms 40 kA rms

sec)
19 Rated peak withstand current kA Peak 100 kA peak
20 Rated auxiliary voltage V dc 110 V dc
21 Rated control motor auxiliary voltage V dc 415 V AC
22 Degree of protection for operating and IP 55

auxiliary cubicle
23 Rated mechanical terminal load N As per IEC: 62271-102/ IS:9921
Earthing Isolator
24 Electrical values As above
25 Earthing isolator operation simultaneous Yes/No Isolator and earthing switches are
with LIS individual operated and a mechanical
interlock provided in between. If
simultaneous operation of Earthing
Isolator and Line E/S to be done at
site through Electrical interlocking.
26 Making capacity Isolator Earthing Switches (Class E0)

are designed for short time withstand
current and not for making capacity.

2.5.3 ISOLATOR INSTALLATION PROCEDURE
2.5.3.1 Fasten the base frame (A) horizontally and vertically levelled to foundation (i.e.
Isolator supporting structure) in such a way that distortion forces cannot effect the
frame. Check levels with spirit level or by water balance method.
2.5.3.2 Adjust the centreline of isolator poles and see that the operating levers are at the
same level.
2.5.3.3 Fasten support insulator stacks (B) on rotating bearing unit (A of 2) and elevator
plate/channel (A of 1)
2.5.3.4 Check the insulator columns vertically (by plumb) and place moving contact arm (D)
on centre support insulator and fixed contacts © on outer support insulator in
opposite direction, see that the terminal pad (C of 2) should be in outer side adjust
and tighten.
2.5.3.5 Adjust the poles individually to have proper entry of the moving contact arm (D) into
the fixed contact © simultaneously at either end by adjusting the elevator (A of 1).
Care should be taken that ll individual poles are to be closed in anti-clock wise
direction only.
2.5.3.6 Place the top operating mechanism (Motor/Manual) as per the layout drawings.
2.5.3.7 Keep all the three poles in close position and keep the top operating mechanism
lever in parallel to the other levers of isolator pole.
2.5.3.8 Fasten the group operating pipe (H) through the fixing clamps to all levers.
2.5.3.9 Place the operating mechanism (G). Due care to be taken while fastening, that the
centre line of top operating mechanism coincides with the centre line of the
operating mechanism.
2.5.3.10 Fix the operating pipe (I) suitably by sizing the height and weld with the vernier
flange. Connect one end to the top operating mechanism and the other end to the
operating mechanism (G) (Motor/Manual) through vernier flange with two bolts.
While connecting see that the operating mechanism is also in ON (close) position.
2.5.3.11 Check the operation manually (by means of operating handle). Care should be taken
that all poles are closing uniformly and simultaneously. If the poles are not closing
properly loosen the fixing clamps of group operating pipe and re-adjust to achieve
proper alignment. After ensuring the proper alignment, tighten all fasteners firmly.
Check few operations and keep the isolator in open position.

2.5.4 EARTH SWITCH INSTALLATION PROCEDURE
2.5.4.1 Place the moving contact (L) in the moving contact fixing assembly and tighten the
clamps.
2.5.4.2 Adjust the moving contact to have proper entry in the fixed contact by adjusting
check bolts.
2.5.4.3 Keep all the three poles in ON (close) position and connect the group operating pipe
(H).
2.5.4.4 Place the top operating mechanism (M). Keep the lever at convenient angle and
connect the auxiliary coupler pipe (N) i.e. one end to the group operating pipe and
the other end to the top operating mechanism.
2.5.4.5 Place the operating mechanism (G). Due care to be taken while fastening that the
centre line of the top operating mechanism coincides with the centre line of the
operating mechanism.
2.5.4.6 Fix the operating pipe (I) suitable by sizing the height and weld with the vernier
flange. Connect one end to the top operating mechanism (M) and the other end to
the operating mechanism (G) through vernier flange with two bolts. See that the
operating mechanism also in ON (close) position while connecting.
2.5.4.7 Check the operation manually (by means of operating handle) to make sure that all
poles are closing uniformly and simultaneously.
2.5.4.8 Connect the mechanical interlock link to the isolator lever arm (Y Phase)
2.5.4.9 Check the mechanical interlock operation between the earth switch and the isolator
properly by adjusting the link pipe (J of 3).

2.5.5 OPERATING INSTRUCTIONS
2.5.5.1 Don‘t operate the isolator when the interlock conditions are not satisfied.
2.5.5.2 Don‘t operate the isolator when the breaker is in ON position.
2.5.5.3 While operating the isolator with manual operating mechanism, open the pad lock
and take the operating handle into horizontal position.
2.5.5.4 By pressing the push button remove the castle key by rotating and insert the key in
top castle lock and rotate. Now the mechanism is free to operate the isolator/earth
switch to close or open. After completion of the operation remove the castle key by
rotating and keep the key inside the cubicle and rotate, keep the handle in the same
position and pad lock it.
2.5.6 MAINTENANCE
After performance of 500 operations few random checks are to be done. While checking
the following important points are to be taken care.
2.5.6.1 Switch off the control/auxiliary supplies to the operating mechanism, and De-
energise the isolator.
2.5.6.2 Check the contacts of isolator, earth switch and arcing contact for contacts wear and
tear and arcing effects. If any deep burnings observed, replacement has to be made.
2.5.6.3 Apply contact lubricant (petroleum jelly) for isolator and earth switch contacts.
2.5.6.4 Apply lubricant (grease or oil) in all rotating parts like rotary bearings, clamp joints
and turn twist mechanism etc.
2.5.6.5 Check the fasteners tightness in all points.
2.5.6.6 Operating mechanisms are to be cleaned and tightness of screws and wires are to
be checked.
No special tools and tackles are required.

2.5.6.7 Lubrication: All points are to be greased as follows:
 LUBRICATING POINTS
a) Rotary Bearings
b) Bush Bearings at clamps
c) Turn and Twist mechanism
d) Isolator/Earth switch contacts
 LUBRICANT TO BE USED
a) Grease by grease guns

b) Grease and Oil
c) Grease and Oil
d) Petroleum jelly or silicon grease 435 GR
2.5.7 MAINTENANCE SCHEDULE
Equipment 66 KV ISOLATOR
Make: M/s G R Power Switchgear Ltd, Hyderabad
1 Check and clean the isolator‘s porcelain insulator for

its cleanliness.
3
Check and tighten the control wirings.
4 Clean the contacts and apply a thin layer of
petroleum jelly to the contact surfaces.
5
Quarterly Maintenance
Operate the Isolator a few times and check for
proper operation locally.
6
Main bearings to be lubricated with grease through
the nipple provided.
7
All other rotating parts to be lubricated with mobile
oil.

8
Check limit switch & auxiliary switch & contacts.
9
Check Movement of Operating Rod
1
All checks from quarterly schedule.
2
Measure insulation resistance. 5 KV megger
3
Checking condition of fixed and moving contacts.
4
Observe for any signs of overheating
1
All checks of half yearly maintenance.
Yearly Maintenance
2 Measure and record insulation resistance of motor
winding and contactor coils using 500 v megger.
Remarks: -
2. Manufactures Instruction & Maintenance Manual shall be referred during Maintenance.
4. All PPE‘s shall be ensured at site during maintenance.

2.6 NEUTRAL GROUNDING RESISTOR
2.6.1.1 The Neutral Grounding / Earthing Resistor (NGR/NER) is passive device to limit earth
fault current. NGR / NER is normally rated for a very short duration of 5, 10, 30 and
60 sec. For certain applications they are also rated for continuous current ratings.
2.6.1.2 The NGR‘S conform to IEEE – 32 standards which is universally followed and it is
also a most comprehensive specification for NGR.
2.6.1.3 The resistors are of Punched plate type grids. They are invariably non-magnetic and
non-corrosive. The Punched Plate type offers non-inductive characteristics. The
resistive material is stainless steel. Stainless Steel elements are adequate for normal
applications.
2.6.1.4 The outdoor enclosure for resistor warrants certain consideration. The heating of
resistor elements requires well-ventilated enclosure and at the same time no
rainwater should enter inside. Any water accumulation, taking place out of
consideration should be drained off from the bottom. But the enclosure is designed
to minimize the ingress of undesirable material and conforms to IP 54 specifications.
2.6.1.5 Because of the usage of stainless steel and ceramics in the construction of NGR, the
resistors can withstand many onerous environmental conditions without any
protection.
2.6.1.6 The operation of the resistor will not be affected by moisture or fine dust or sand
provided they are not unduly conductive. The stainless steel resistor units are
virtually corrosion proof and immune to progressive pitting and rusting. The ceramic
glazed insulators are not affected by exposure to condensation and repeated heating
cycle of resistive elements.
2.6.1.7 The resistor unit will consist of many resistor banks. Support insulators support each
bank independently. Sometimes a set of resistor banks will be mounted on post
insulators.
2.6.1.8 The type of resistive element will be identical in all the resistance banks of NGR‘S of
same ratings. In the assembly of the resistors only hardwares of stainless steel are
used. The individual elements are connected by bolt and nut instead of welding. This
will facilitate easy replacement of individual resistance elements. Also the entire
assembly can be reconstructed for any desired ohmic values but for same current
rating at site.

2.6.1.9 The general arrangement of Neutral Grounding Resistor has been shown in Fig.
2.5.1 below:
Fig. 2.5.1: NGR General Arrangement


The technical parameters of Neutral Grounding Resistor are provided in Table 2.5.1
below:
Table 2.5.1: NGR Technical Parameters
A General
1 Manufacturer NATIONAL SWITCHGEARS
2 Place of manufacture Chennai-600098.
3 Manufacturer drawing reference Nil
B NGR
1 Type Metal in Air
2 Nature of the active part Stainless Steel
3 Rated insulation voltage kV 24KV
4 Rated value  19
5 Allowable tolerance on measurement % ± 5%

(at 20°C in DC)
7 Rated operating cycle
thermal stabilization at In=5A °C 47

°C
Heating-up at I-20 A, 10 minutes °C 55
Heating-up at I-1000 A, 30 seconds 550
8 Value of the resistance after operating  19

cycle, at 45°C ambient temperature
9 Protection degree IP 55
10 Dimensions
Length mm 1800
Height mm 2200

Depth mm 1800
Weight kg 1550
2.6.3 Operation
2.6.3.1 Operating Conditions
Maximum ambient Temperature: 50C

Maximum Humidity : 95%
Maximum altitude : 1000m from sea level
2.6.3.2 General Operating Mechanism
2.6.3.2.1 The switch has base frame (1) and two cast resin epoxy insulators (2) per phase for
support.
2.6.3.2.2 The switching are has two identical fixed contacts (3) ( for incoming and outgoing)
and moving contacts (4) of adequate capacity and it is operated by specially
designed insulating material called lifting arm (6) standard provision is available for
fixing HRC Fuses by extending the base frame with one more cast resin insulator
added on it.
2.6.3.2.3 An arcing blade (7) is fixed along the main blade and it will operate inside the flat
arc chute (8) the mechanical arrangement is so assembled using spring mechanism,
the main contact closes and opens first and then the arcing contact.
The flat arc chute quenches the arc by the gas emanating in the arc chamber.

2.6.3.2.4 The stock of torsion springs (9) are housed in between the main driving shaft (10)
and the fixed shaft (11) which is bolted to the hollow shaft (12) stores the energy
when the operating handle is operated.
2.6.3.2.5 The switch has cam latches mounted in the base frame for closing (13) and opening
(14). The main driving cam coupling (15) is in the left and right side. The cam
coupling is restricted to rotate by opening and closing latches.
2.6.3.2.6 When the main operating shaft is operated, the springs are energized and the
energy is transferred to the hollow shaft through the fixing shaft. High speed
switching of the blades follows immediately. Shut tip mechanism is not possible in
this arrangement. The operating side can be changed (i.e.) either left or right side
easily by shifting the opening and closing latches.
2.6.3.3 CAUTION for Manual Operation
2.6.3.3.1 When the switch is in tripped condition, to close the Disconnector manually, the
handle must be rotated in the anti-clockwise direction till the nosed lever locks with
the grooved shaft, and then the handle has to be operated in the clockwise
direction.
2.6.3.3.2 The doors should not be opened when the switch is operated electrically. If it
happens in the middle of the operation the Disconnector has to be operated
manually to close or open.
2.6.4.1 The design of the NGR the quality of the materials and the skilled workmanship are
such that it requires practically no maintenance whatsoever. The performance
reliability is guaranteed without any routine maintenance for considerably a long
time.
2.6.4.2 In view of hazardous nature of the terrain with lots of thunderstorms harsh and
unpredictable climatic conditions with heavy rains, soaring temperature coupled with
humidity prevailing at the site where the NGR is installed, the following maintenance
instructions are given.
a) Inspect the High end and Low end bushings for any damage, looseness of fasteners
or any foreign material sticking to the bushing. Take appropriate action to replace
damaged bushings and clear the defects.

b) Remove covers and inspect the resistance grids, the connections from the H.T.
bushings down to the Low-end bushings and the copper bus bars. If anything is
found loose or damaged the same should be replaced / tightened. Loose nuts and
bolts on the grids will invite arcing.
c) After carrying out the replacement of grid separator ceramic bushes, the grid
connecting stainless steel bushes and the associated hardware‘s are to be tightened
properly to avoid the change in ohmic values and heating up of contacts.
d) Finally use a hot blower to remove the ingress of moisture and dust accumulated in
the enclosure.
e) After carrying out the visual inspection and repair, the following routine tests are to
be conducted to ascertain the proper functioning of the equipment.
Insulation Resistance Test (Using 5 KV Megger)
Ohmic value measurement by Digital Micro Ohm Meter or Wheatstone bridge.
2.6.4.3 Methods to be followed to replace the resistor elements.
a) The particular resistance bank where the element got damaged is to be

removed by loosening the fasteners at tray end. By sliding the bank the same
can be pulled out.
b) The interconnecting fasteners of the elements are to be removed and the

elements should be made free for removal.
c) For taking out the burnt-out elements, the tie-rods, which are holding the
elements, are to be loosened and the side trays are to be removed. Now the
elements can be replaced easily.
d) After replacing the elements, the re-assembly of the bank can be carried out
and put back in its assigned place.


Equipment NEUTRAL GROUNDING RESISTOR
Make: M/s NATIONAL SWITCHGEAR
1
Check for general cleanliness of the equipment.
2 Check all connections of resistance in panel.

3 Measure total resistance of NGR circuit. It should be
20 ohm.
4 Check all earth connections and tighten them.
5
Check isolator and clean the contacts with kerosene

Quarterly Maintenance oil and apply Vaseline lightly.
6
Check pedestal insulator and clean them with dry
cloth.
7
Check connections with LA, CT and earth, if loose
tighten them.
8 Check neutral connection of transformer to NGR

and tighten them.
1
All checks from quarterly maintenance schedule.
2 Measure IR value of CT & LA with 500 V megger as

per the specified value.
3
Check gasket for water proofing.
1
All checks from half yearly maintenance schedule.
Yearly Maintenance
2
Touch up paint if required.

Remarks: -
1. Always follow the instruction and Maintenance Manual of the manufacturer.

2. All safety precautions shall be taken during Maintenance.
3. Standard tools and accessories as per Instruction and Maintenance Manuals shall be
4. All Drawings and Manufacture‘s Instruction & Maintenance manual shall be ensured at

CHAPTER – III

1.0 AUXILIARY SUBSTATIONS

1.1 Overview
The power at 33 kV level from the 33 kV switchgear room located in the Receiving
Substations (RSS), is transmitted to the Auxiliary Substations (ASS) located at the
passenger stations and depots, through 33 kV cables. The 33 kV power is transformed
to 415 V power by means of 33 kV / 415 V Cast Resin Dry type transformers of suitable
capacity installed in the ASS‘s.
1.1.1 Each auxiliary substation consists of 33 kV circuit breakers, 33 kV interrupters, auxiliary

transformers and AC/DC control power supply system.
1.1.2 All the ASSs of elevated stations are provided with one ASS having 2 x 500 kVA
transformer, while all the underground stations are provided with two ASSs each having
1 x 2000 kVA transformer.
1.1.3 Both the depots are provided with one ASS having 2 x 2000 kVA transformers. In
addition, one 2 x 500 kVA ASS is provided for the Operation Control Center (OCC)
physically located in Baiyappanahalli Depot.
1.2 ASS Types
1.2.1 Type A: 2 x 500 kVA
This type of ASS is applicable to all elevated stations and at-grade stations (and OCC--
ASS) except Mysore Road, Baiyappanahalli, Puttenhalli and Peenya Village.
Each transformer at these ASSs receives power from separate two ring main 33kV
feeder cables.
1.2.2 Type B: 2 x 500 kVA with 33kV Incoming Feed
This configuration is similar to Type-A with the addition of an incoming 33kV feeder from
the Receiving Substations. This type of ASS is applicable for elevated stations -
Baiyappanahalli, Peenya, Mysore Road and Puttenhalli stations.
1.2.3 Type C: 1 x 2000 kVA
This type of ASS is for underground stations and will be applicable to all underground
stations with the exception of Kempegowda station.
Two such auxiliary substations are provided for each underground station (except
Kempegowda). The transformers at these ASSs receive power from the two ring main
33kV feeder cables.

1.2.4 Type D: 1 x 2000 kVA with Interconnection Cables
This configuration is similar to Type-C with the addition of 33kV interconnecting cables
between the EW and NS Corridors. This type of ASS is applicable to the underground
Kempegowda stations of both the corridors.
1.2.5 Type E: 2 x 2000 kVA
This is similar to Type-A with the exception that each auxiliary transformer is 2000 kVA
rating instead of 500 kVA. This type of ASS is applicable to both the depot ASSs.
Each transformer at these ASSs receives power from the separate two ring main 33kV
feeder cables.

2.0 TRACTION SUBSTATIONS
2.1 Overview
2.1.1 The rolling stock is provided with traction power at 750 V dc. For this purpose, power at
33 kV level from the 33 kV switchgear room is transmitted to the Traction Substations
(TSS) located along the corridors, in the premises of passenger stations and depots,
through feeders of 33 kV insulated cables.
2.1.2 The 33 kV power is transformed to 750 V dc power by means of 33 kV / 292-292 V

Cast Resin Dry type rectifier transformers and rectifier of suitable capacity installed in
the TSS‘s.
2.1.3 TSS includes 33 kV/292-292 V, 2850 kVA rectifier transformers, 2500 KW rectifiers, 33
kV ac and 750 V dc switchgears (including high speed circuit breakers), protection and
control unit, indication and metering arrangement, ac/dc control source and systems,
750 V dc positive and negative cables, protective provisions related to electrical safety
and earthing etc, with all accessories and auxiliary equipment.
2.1.4 The traction system for mainlines is that of floating negative / return system so that
stray currents are controlled. However for safety reasons, the systems in depots are
negative earthed one. Therefore, the mainline tracks are isolated from depots tracks
through insulted rail joints in order to minimize the stray currents.
2.1.5 A separate traction substation is therefore provided in depot, so as to facilitate isolation

of depot traction power supply from mainline in order to prevent the leakage of return
currents to main line. Remote operated sectionalizing switches are provided to feed
power from depot to main line equipment and vice-versa in case of failure of TSS.

2.2 TSS Types
2.2.1 Type-A: With two 33kV Ring Main Cables
This is the most common type of TSS and this is applicable to all TSSs except - two
depot TSS, two Majestic TSSs (one each for EW & NS corridor respectively), and Jalahalli
& Peenya Industrial Area.
TSS at these stations receives power from the two ring main 33kV feeder cables and
two rectifier-transformers are fed from 33kV busbar in the TSS.
2.2.2 Type-B: With two 33kV Ring Main cables and one Interconnecting Cable
This type of TSS is similar to Type-A with an additional 33kV switch, which connects to
the adjoining TSS. This design is applicable to two TSSs viz. Jalahalli and Peenya
Industrial Area TSSs. These are the TSSs which are located on either side of RSS.
TSS at these stations normally receives power from the two ring main 33kV feeder
cables, one of which is coming directly from RSS.
In an emergency case of RSS being in outage, the feed can be extended from other RSS
through the additional interconnecting 33kV cable. This ensures extension of 33kV feed
without the necessity of routing it through the 33kV busbar in faulty RSS.
The two (presently one and are to come in future) rectifier-transformers are fed from
33kV busbar in the TSS like in the Type A.
2.2.3 Type-C: Majestic TSSs
Majestic TSSs (both for EW and NS Corridors) are different for two reasons:
Majestic TSSs are the end of 33kV traction ring in normal feeding scenario, thus
requiring closing of the 33kV ring; and
The 33kV interconnection between EW and NS corridors are provided at this location, as
this station being an integrated one.
The 33kV busbar is provided with a bus coupler dividing the busbar into two sections.
One of the sections feeds the two rectifier-transformers in addition to acting as closing
the concerned 33kV ring. The other section works to close the other side 33kV ring with
the bus coupler (normally open) providing the possibility of emergency feed extension
from other 33kV ring (i.e. from other RSS).
From both these sections of 33kV busbar, interconnecting 33kV cable is provided to
interconnect 33kV network of EW and NS Corridors. One end of these interconnecting
cables is normally open and only in emergency case; the 33kV supply is extended from
one corridor to another.

2.2.4 Type-D: Depot TSS
As RSSs are physically located in both the depots, the depot 33kV supply for TSS and
ASS is directly drawn from respective RSS in the 33kV ring main feeding formation.
Depot TSSs receives power from separate two ring main 33kV feeder cables and two
rectifier-transformers are fed from 33kV busbar in the TSS.
2.3 ASS EQUIPMENTS
The Auxiliary Sub-Station includes the following equipments:
a) 33 kV Switchgear
b) Dry Type Auxiliary Transformer (200 kVA, 500 kVA & 2000 kVA)
c) ACDB
d) DCDB
The Guaranteed Technical Parameters of the individual ASS equipments, their operation
provided below:
2.4 TSS EQUIPMENTS
The Traction Sub-Station includes the following equipments:
a) 33 kV Switchgear
b) HSCB (High Speed Circuit Breaker)
c) Rectifier
d) Rectifier Transformer
e) Short Circuiting Device
f) Negative Return Panel
The Guaranteed Technical Parameters of the individual ASS equipments, their operation
provided below:

2.5 33 kV SWITCHGEAR
2.5.1.1 The basis for the design of switchgear panel is the incoming/outgoing feeder
panel with vacuum circuit breaker using insertion technology. It is divided into
busbar compartment, circuit-breaker compartment, cable compartment and
control cabinet for the secondary equipment.
2.5.1.2 The enclosure and internal partitions of the panels are of 2mm thick high quality
steel sheets. The three high voltage compartments (busbar compartment, circuit-
breaker compartment and the cable connection compartment) are equipped with
top-mounted and secured pressure relief flaps. These open in the case of over
pressure due to an internal arc fault.
2.5.1.3 The front of the panel is closed by pressure resistant doors. Cable and circuit
breaker compartments have independent doors. The circuit-breaker
compartment is equipped with inspection window made of security glass.
2.5.1.4 Panels are partitioned from one another by the side walls of each panel. The
enclosure is provided above by top-mounted pressure-relief flaps which,
according to the rated branch conductor current, are made of sheet steel with
wire mesh or plain sheet steel. The pressure relief flaps are secured with steel
screw on one longitudinal side with plastic screws. In case of internal
overpressure, the plastic screws are the point of rupture.
2.5.1.5 Door and rear walls as well as cover plates are thoroughly cleaned and treated
against corrosion before receiving a high quality double coating of paint.
2.5.1.6 The circuit breaker compartment and cable connection compartment doors are
pressure resistant and can either fitted with screws or manual closing system.
2.5.1.7 Normal operating conditions:
The switchgears are basically suitable for normal operating conditions for indoor
switchgears and switchboards in accordance with IEC 60694/ IEC 62271-1. The
following limit values, among others, apply:
 Ambient temperature:
a) Maximum + 40 °C
b) Maximum 24 h average + 35 °C
Minimum (according to ―minus 5 indoor class‖) - 5 °C
The maximum site altitude is 1000 m above sea level.

2.5.2 Structure & Design of Panel Compartments
2.5.2.1 Bus Bar Compartment

The bus bars have 3 tubular cross-section made of copper and are laid in sections
from panel to panel. These are held by flat branch conductor. No special connection
clamps are needed. Bus bars & branch conductors are insulated and connections are
shrouded.
2.5.2.2 Circuit Breaker Compartment

The circuit breaker compartment contains all the necessary equipment for reciprocal
operation of the withdrawable part and the panel. It is metallically partitioned on all
sides. The shutters are opened by means of actuating bars of the withdrawable
circuit breaker part, using lever when inserting into the service position, and are
closed when the latter is removed.
In the Test/Disconnected position, the withdrawable part is still completely inside the
panel with door closed. The ON/OFF pushbutton located on the CB, and the
mechanical indicators for ON/OFF and CHARGED/DISCHARGED can be observed
through an inspection window.
2.5.2.3 Withdrawable Parts
a) Withdrawable Circuit Breaker Parts
The withdrawable assembly establishes the mechanical connections between the

panel and the circuit breaker.
The fixed part is connected to the panel by forking, which is form coded on both
sides. The moving part with the circuit breaker is moved manually by means of a
spindle, between the service or test/disconnected positions with the front doors
closed.
The earthing connection between the withdrawable part and the panel is established
by its roller and travel rails which are bolted on to the panel.
b) Other Withdrawable Parts
The withdrawable part can also be fitted with the following trucks:
 Metering voltage transformers trucks with fuses
 Earthing truck without making capacity (for main busbar system and power
cables)
 Earthing truck with making capacity (for main busbar system and power
cables)
 Power cable testing trucks
 Isolation trucks
 Isolation truck with fuses

2.5.2.4 Cable Connection Compartment

The cable compartment contains Current Transformers, Fixed & Withdrawable
Voltage Transformers and Earthing Switch.
The cable compartment is constructed for installation upto three current

transformers.
The voltage transformer mounted fixed are connected on the primary side with
connectors. The removable voltage transformers are fitted with HRC fuses.
The earthing switch can be used with either a manual or motor-operated

mechanism. Its switching position is indicated both mechanically and electrically by
means of the auxiliary switch.
2.5.2.5 The structure of 33 kV switchgear panels is shown below:
Fig 1.2.1: Complete Cubicle Assembly

Table 1.2.1: Technical Parameters for 33 kV Switchgear
A General
1 Manufacturer ABB
2 Place of manufacture Nasik, India
3 Standards IEC 62271-100 / 200
B CUBICLE (FIXED PART)
1 Class Indoor
2 Rated insulation voltage kV 36KV
3 Rated operating voltage kV 33KV
4 Rated frequency Hz 50Hz
5 Rated short time duration power kV rms 70


voltage
7 Cubicle rated current
All CB except aux. transformer CB A 1250
Aux. transformer CB A 400
8 Bar set rated current A 1500A
9 Allowable over current for 1 second kA rms 14KA
10 Instantaneous over current kA peak 35KA
11 Number of flip-flop contacts for circuit- Minimum 2 NO + 2 NC

breaker plugging-in and plugging-out

monitoring
12 Number of flip-flop contact for earthing Minimum 2 NO + 2 NC

isolator open/closed position
monitoring
13 Number of flip-flop contacts for Minimum NA

isolator open/closed position
monitoring
14 Maximum dimensions of the cubicle
a. Width mm 1000 mm
b. Depth mm 2800 mm
c. Height mm 2600 mm
d. Depth with circuit breaker plugged out mm 3700
15 Protection degree IP41 for Switchboard
16 Earthing isolator making capacity kA 5
C CIRCUIT-BREAKER (MOVABLE
PART)
1 Type Three Pole
2 Rated insulation voltage kV 36
3 Rated operating voltage kV 33
5 Rated short time duration power kV rms 70


voltage

7 Rated current
All CB except aux. transformer CB A 1250
Aux. transformer CB A 400
8 Allowable over current for 1 second kA rms 14KA
9 Instantaneous over current kA peak 35KA
10 Breaking capacity kA rms 14KA
11 Making capacity kA peak 35KA
12 Breaking mode Vacuum
13 Opening time ms ≤ 70
14 Breaking time ms ≤ 80
15 Closing time ms ≤ 100
16 Rated operating cycle O-0.3sec-CO-3min-CO
17 Breaking capacity of cable at no load A As per IEC
18 Number of auxiliary contact for O/O 8 NO + 8 NC

open/closed position of the circuit-
breaker O/C
19 Auxiliary supply voltage V dc 110
20 Supply voltage for motor drive circuits V dc 110
21 Allowable variation range of supply +10%, -15%

voltage
22 Coils consumption: 200 W
- engagement coil A
- release coil A
23 Consumption of arming motor A 350 W

24 Maximum noise level during opening Within Audible Limits

and closing actuation
dB
25 Degree of protection for auxiliary IP 41 for Switchboard

circuit
26 Trolley design (Will be suitable for Offered switchgear is with Cassette

direct withdrawal on Floor) Mounted Circuit breaker. Breaker
transport trolley separate.
D CURRENT TRANSFORMER
1 Type Cast resin
2 Manufacturer Pragati/ECS
3 Place of manufacture Mumbai/ Vadodara
4 Standards IEC 44-1 / IS 2705
5 Rated insulation voltage kV 36
8 Rated power frequency short duration 70

withstand voltage
kV

voltage
10 Actual transformation ratio (As A As per Approved RSS SLD

required for different purposes to be
indicated. The value provided in
‗required‘ column is indicative only)
11 Protection secondary As per Approved RSS SLD
- Accuracy class

- Rated output (Burden) VA
12 Measuring secondary
- Accuracy class As per Approved RSS SLD
- Rated output (Burden) VA
13 Short-circuit current allowable for 1 kA 14

seconds
14 Permanent operation without danger In 1.2*In
15 Over current class 1.2 Continuous
16 Temperature rise over 40 °C ambient °C As per IEC / IS
E VOLTAGE TRANSFORMER
1 Type Cast Resin
2 Manufacturer Pragati/ ECs
3 Place of manufacture Mumbai/ Vadodara
4 Standards IEC 44-2 / IS 3156
5 Primary insulation voltage kV 36
8 Rated short-time duration power 70

kV

voltage
10 Actual transformation ratio As per Approved RSS SLD
- Primary winding kV

- secondary windings V
11 Accuracy class
Protection core 3P
Measuring core 0.5
12 Rated output (minimum)
Protection core VA 50
Measuring core VA 100 (For Bus PTs)
(As required for different purposes to 50 (For LPTs)

be indicated. The value provided in
‗required‘ column is indicative only)
13 Secondary winding type and insulation Metering Winding & Graded

Insulation
14 Secondary winding voltage grade V 660
15 Secondary winding conductor material Copper
16 Earth bus 30 x 10 mm
F Finish of Switchgear
1 Inside and outside the panel Only Front Doors are with epoxy
powder painting.
G Internal wiring of panel
1 Elevated / at-grade sections FRLS
2 Underground sections FRLS- Zero Halogen

H NUMERICAL RELAYS
1 Manufacturer ABB
2 Place of manufacture ABB Vadodara
3 Relevant Standards IEC 255 / IS 3231
4 Protections As per Approved RSS SLD
5 Communication Protocols IEC 61850
6 Auxiliary Supply V DC 110

2.5.4 Operating Mechanism
The switching operations must be carried out with the front doors closed.
2.5.4.1 Withdrawable Apparatus
 Connect control wiring plug.

 Close the front door
 Ensure that the apparatus is in OFF position.
 Fit hand crank on square spigot of the spindle mechanism after opening the hole for
them by turning slide.
 Turn the crank clockwise (30 Turns) until the stop is reached and the withdrawable part
is in the service position.
 Observe the position indicator.
 Remove hand crank.
 It must be considered that the spring loaded pin head will lie completely on the rear side
of the panel door when the hand crank is moved from square spigot of spindle
mechanism.
 This ensures that the rear part of the pin head has been shifted onto the hexagonal cap
of the spindle and prevents unintentional wrenching of the spindle during panel service.
 The withdrawable part must not be stopped in any intermediate position in the travel
range between the service and test/disconnected position.
 Manual withdrawal from the service position into the test/disconnected position:
 Ensure that the apparatus is in OFF position.

 Reverse the procedure described above for insertion into the service position.
Note: The force normally applicable to the insertion/withdrawing lever is 260 N. In any
case, the maximum applicable force must never exceed 400 N.
2.5.4.2 Circuit Breaker
a) Charging the stored energy system:

 On the circuit breaker with charging motors, charging is carried out
automatically.

 For manual charging, open the door with the withdrawable part in the
disconnected position; pump the integrated charging handle approx 10 times
until the charged condition is indicated.
 When the charged condition is reached, the charging mechanism is
automatically disengaged and any further strokes of the lever have no effect.
Pumping is effective, If the lever is moved in the angle of 90 degree.
b) Opening & Closing of the Circuit Breaker

 Opening and Closing operations with the withdrawable part in the service
position should only be performed with the door closed.
 Operate the local or remote electrical control.
 Observe the switch position indicator.
 Press the relative mechanical pushbutton, having previously turned knob
anti-clockwise to the stop if the withdrawable part is in the service position.
 Observe the switch position indicator
2.5.4.3 Earthing Switch
 The earthing switch has a snap closing mechanism which is independent of

the rotation of the drive shaft.
 An earthing switch allocated to a circuit breaker is only enabled for switching

when withdrawable part is in the test/disconnected position or removed from
the switchgear panel.
 Only turn earthing switches on when the doors are closed.
2.5.4.4 Withdrawable Metering Parts
 Withdrawable metering parts in incoming & outgoing feeder panels are put
into the cable compartment using a ramp.
 They reach their service position immediately and engage in the panel
earthing by means of the racking frame at the sides.
 The voltage transformers used correspond to the type used in the metering
panel, and therefore HRC fuses can also be used along with the voltage
transformers.

2.5.5.1 Inspection
 Where necessary, the working area must be isolated and secured against
reconnection.
 Correct condition of the switchgear should be monitored by regular

inspections.
 Inspection is primarily to carry out a visual check for grime, corrosion and
moisture.
 Effects of high temperature on the main circuits

 Traces of partial discharge on the insulating material parts
 Traces of leakage current on the insulating material parts
 Surfaces of the contact system
 However, Inspection must also to include correct mechanical/electrical

operation of the parts viz. switching devices, actuating, interlocking,
protection and signaling devices.
 No partial discharge must occur on the surfaces of equipment at operating

voltage. This can be detected by characteristic noises, a clearly perceptible
smell of ozone, or visible glowing in the dark.
 Visually checking the contact system, it is recommended to turn the system

alternately in order to clean the inner contact points of the contact system.
The contact points should be cleaned if signs of overheating (discoloured
surface) are visible.
2.5.5.2 Servicing
 Where necessary, the working area must be switched off and secured against
reconnection.
 Clean the surfaces in general:
 Weakly adhering dry dust deposits: with a soft dry cloth.

 More strongly adherent grime: with mildly alkaline household cleanser or
with Ethanol F 25 M.
 Clean insulating surfaces and conductive components with Ethanol F 25 M.
 Wipe down after cleaning, using clean water, and dry properly.
 Should partial discharges occur as a result of condensation, application of a

thin silicone film on the surface concerned is often effective as a temporary
remedy.

Equipment 33 kV Switchgear Panel

Before shutdown note down the readings of the meters and check
1
all the indicating lamps after shutdown if abnormality is found
Check after shutdown the Metal structures.
2 Check for Presence of dirt, grease or dust.
3 Check the Hinges, Locks, gaskets
4 Check the Mechanical Interlocks
5 Check and inspect visually the Current Carrying contacts
6 Check the Tightness of guide rail and connections for MVCBs

Check the Insulation Resistance by 5000 V megger value should be
7 >1000Mohm
Check the Earthing connections

Half-Yearly 8
Maintenance Check the rack in and rack out of the CBs
9
10 Check the CTs and PTs if meters were found not working.
11 Check the operation of the U/V relays
12 Check the PT compartment for any abnormalities visually.
13 If voltage is missing, then check the PT fuses.
14 Check all the selector switches for proper operation.
15 Check the signals from SCADA
16 Check the operation of the CBs locally and from SCADA
17 Check the mechanical indications of the CBs
18 Check the incoming and outgoing cables.

Check the relays and inform the service personnel if any
19 abnormality is found.

1 All checks from quarterly maintenance
2 Any touch up paint required to be done.
Yearly Maintenance 3 IR value of PTs, CTs
4 Secondary resistance of CTs, PTs
5 Check the Bus bar tightness
Remarks: -
1. Ensure that the equipment is disconnected from all electrical supply. Earth
them at both ends before carrying out any maintenance work.
2. Always follow the instructions laid down in the Instruction and Maintenance
Manual of the equipment manufacturer.
4. Standard tools and accessories as per Instruction and Maintenance Manual
shall be ensured for facilitating the normal maintenance activities on the
equipment.
5. All Drawings and Manufacturer‘s Instruction & Maintenance manual shall be
ensured at site for reference during Maintenance.

2.6 DRY TYPE TRANSFORMERS
Auxiliary Transformer (200 kVA)
Fig 1.3.1: General Arrangement of Auxiliary Transformer (200 KVA)

The technical parameters of Dry Type Transformer are as below:
Table 1.3.1: 33 KV/415V Auxiliary Transformers GTP (200 kVA)
SN Description Unit of Values

Measur
ement
1 Type Dry type cast resin
2 Name of the manufacturer ABB
3 Country of manufacture Korea
4 Port of embarkation Busan
5 Manufacturer drawing reference ABB
6 Relevant Specification IEC 76, IS 2026, IS 11171
7 Insulation type Cast resin
9 Frequency Hz 50
10 Vector group Dyn11
11 Nominal rated power kVA 200
12 Cooling Mode Air
13 Primary rated insulation voltage kV 36
15 Secondary system highest voltage V 1.1kV
16 Secondary rated operating voltage V 415/240




Measur
ement

winding
20 Rated lightning impulse withstand kV 3.5

21 Percentage Impedance % 4.0
22 Voltage setting (off load tap changer) % -5.0, -2.5, 0,
+2.5, +5.0
23 Winding material aluminium
24 Max. efficiency 98.38
25 % loading at maximum efficiency 75% at pf 1.0
26 No load loss at rated voltage kW 1.05
(refer to ITT for capitalization of

losses)
27 Copper loss at rated voltage kW 2.5

losses) (at 75℃)
28 Total loss at rated voltage kW 3.55

losses) (at 75℃)
29 Impedance at rates current and % 4.0

frequency
30 Reactance at rated current and % 1.21

frequency
31 Voltage regulation at full load % 1.35


Measur
ement
32 Type of core Core type(step-lap)
33 Weight
a. Core Kg 1050
b. Winding Kg 320
c. Total(TR + Enclosure) Kg 2450
34 Dimensions(enclosure)
a. Length Mm 2300
b. Width Mm 1800
c. Height Mm 2100
d. Overall for packages Mm 2700x2200x2500
35 Max Noise level dB 65
36 Enclosure housing IP31

2.6.3 Auxiliary Transformer (500 kVA)
Fig 1.3.2: General Arrangement of Aux. Transformer (500 kVA)

The technical parameters of Auxiliary Transformer (500 kVA) are as below:

Measure
ment
9 Frequency Hz 50
12 Cooling Mode Air




Measure
ment

winding

+2.5, +5.0

losses)

losses) (at 75℃)

losses) (at 75℃)

frequency

frequency


Measure
ment
33 Weight
a. Core Kg 1800
b. Winding Kg 490
c. Total(TR+Enclosure) Kg 3600
a. Length Mm 2400
b. Width Mm 2000
c. Height Mm 2400

2.6.5 Auxiliary Transformer (2000 kVA)
Fig 1.3.3: General Arrangement of Aux. Transformer (2000 kVA)


The technical parameters for Auxiliary Transformer (2000 kVA) are as below:

Measure
ment
9 Frequency Hz 50
12 Cooling Mode Air




Measure
ment

winding

+2.5, +5.0

losses)

losses) (at 75℃)

losses) (at 75℃)

frequency

frequency


Measure
ment
33 Weight
a. Core Kg 3990
b. Winding Kg 1200
c. Total(TR+Enclosure) Kg 7100
a. Length Mm 2800
b. Width Mm 2400
c. Height Mm 3000
2.6.7 Transformer protection.
The following protections are essential to ensure the reliability and operation of the
transformer.
2.6.7.1 Protection from over currents and overheating.
The transformer must be protected from the thermal and dynamic effects caused by
over currents and short-circuits.
For this purpose there should be an automatic diverter switch or short-circuit fuses
which take into account the possible overloads and are calibrated to prevent currents
from passing that are 1.5 or 2 times greater than the specified current.

2.6.7.2 Ventilation of the transformer cell.
There is suitable ventilation to stop the transformer from overheating above the limits
established by the standards.
If the transformer is mounted inside a cell, it should be ensured that it is well-ventilated

and that it is of the correct size to allow air to pass in and out.
The transformer must be located at least 100 mm away from the cell walls and its
bushing must be at least 350 mm from the cell roof and walls.
2
The input E and output S surfaces should have at least the surface areas in m given by
the following formulas:
E = P / (5.4 x √H)
S = 1.15 E
Where:
H = Distance between the centers of openings, expressed in meters.
P = The sum of the no-load and full-load losses of the transformer in kW.
NOTE: This formula is valid for a maximum room temperature of 40ºC and a max.
Altitude of 1000 m.
The following should be avoided:
 The ambient air temperature should not exceed that indicated by the
standards.
 The transformer should not be installed in small rooms with blinds or
metallic walls exposed to direct sunlight.
 The air for cooling the transformer should not be aspired or expelled in
the same room in which it is installed.
 The transformer should not be installed in premises that are destined for
other uses; in particular in those in which there are machines that work at
high temperatures: boilers, steam generators, etc.
 If the transformer cannot be installed in premises with sufficient natural
ventilation, forced ventilation should be used.
2.6.8 CONNECTIONS
Coupling
When the transformer is connected to the H.V. and L.V. circuits the connections should
be carried out in such a way that they do not exert any strain on the terminals and
should have a large enough section to prevent excessive heating. They should also be
able to dilate.

It is important to make sure of a suitable connection and tightening of all the bolts.
 Using an ohmmeter check the continuity of the circuit with the tap
changer in all of the positions as well as checking that the bridges are
correctly fixed in the working position.
 The enclosure or lower flange of the transformer should be securely and

permanently connected to earth by means of the earthing screws on the
bottom right of the two larger, lower, opposite faces of the enclosure or
flange.
2.6.9 Parallel Operation
If the transformer has to be parallel-coupled to other transformers, check that it fulfills

the voltage compatibility conditions established by the standards, check the position of
diverter switches, impedance voltage and connections unit.
As per standards no. IEC 60076-4 and IEC 60606-4.
 Identical rated voltages and frequencies (voltage tolerance 0.5%).
 The transformers should belong to the same vector group.
 Identical short-circuit voltage (tolerance +/- 10%)
 Power ratio of (maximum) 1/3 at continuous load.
2.6.10 Ground Connection
Permanent and adequate grounding is essential for the enclosure, core and coil
assembly of transformers. Grounding is required to remove static charges that
accumulate, as well as protect the equipment should the transformer windings
accidentally come in contact with the core or enclosure.
To ensure a solid core ground, transformers have copper straps embedded in the core
laminations and securely connected to the lower flame.
The transformer is equipped with two ground terminals, one on each side of the lower
flame. Main grounding must be connected to one of these ground terminals or ground
pads as shown in following fig.

2.6.11 Tap Connection.
Voltage regulation (± change over) must be done by the no load tap changer which is
attached to the high voltage winding. Following fig. is the general type of tap changer.
Before changing tap make sure transformer to be de-energized.

The voltage steps are indicated on the nameplate. On dispatch, the transformer is
connected in the rated position.
When changing the voltage the tap connector must be moved to the required position.
The tap connections should be re-tightened and locked in such a way that they do not
exert any strain on the terminals and should have a large enough section to prevent
excessive heating.
Using an ohmmeter check the continuity of the circuit with the tap changer in all of the
positions as w ell as checking that the bridges are correctly fixed in the working position.
2.6.12 Cable Connection
The cable is connected to the insulator on the upper yoke, or connection terminals on
the coil. To ensure good connection between terminals and the connecting cables, the
contact plates must be cleaned for anti-oxidization. This is very important in order to
ensure a low connecting resistance and to avoid the heating of the screw connections.
When dispatched from the works the contact plates are cleaned.
When connecting terminals, confirm the sign of each phase.

When connecting transformer terminals with cable, the cable should be supported to
cubicle or other place solidly.

2.6.13 Bus Connection
When transformer terminals are connected with bus duct, it is necessary to use flexible
bus bar. If transformer terminal with bus duct is connected directly without flexible bus
bar, vibration of transformer may cause damage to bus duct or increasing of noise.
To ensure good connection between the low voltage bushings and the bus bars or the
connecting cables, the contact plates must be cleaned for oxidization. This is very
important in order to ensure a low connecting resistance and to avoid the heating of the
screw connections.
When dispatched from the works the contact plates are cleaned and covered with
silicone grease as a protection against oxidization. For the first connection it is therefore
sufficient to remove the silicon grease immediately before the connection is carried out.
Table 1.3.5
Size- Flat Washer Conical Washer Current Per Screw (A)
Bolts & (mm)
Nuts
No. Dimension One-side Both-side
(mm) Connection Connection
M10 Ф 10.5/21 x 1.1 2 Ф 10.5/23 x 250 400
2.5
M12 Ф 14.2/28 x 1.5 2 Ф 13.0/29 x 500 750
3.0
M16 Ф 16.3/34 x 1.5 3 Ф 17.0/39 x 800 1250
4.0
2.6.14 CHECKS TO BE CARRIED OUT BEFORE PUTTING THE TRANSFORMER

INTO OPERATION
Checks
The transformer is supplied ready for installation but before proceeding to put it into
operation, following checks should be carried out:
 All of the recommendations indicated in Topics – Installation & Connections

should be checked.
 The transformer should be cleaned with a vacuum cleaner to eliminate any
dust.
 Check the thermal protection device
 Check insulation resistance according to the following table:

Table 1.3.6
Insulation Test Voltage Minimum Value in MΩ (≥)
Between:
HV / LV 5.000 Volt 1 per kV Ampere Turns
HV / Earth 5.000 Volt 1 per kV Ampere Turns
LV / Earth 2.000 Volt 2
2.6.15 Putting the Transformer into operation:
Once the transformer has been connected to the H.V. mains:
 Voltage will be applied in a non-load state and observed for one hour. No
anomalies should occur during this period of time.
 Afterwards charging, after storage or disconnection during a prolonged

period, first it is recommendable to connect the transformer during four
hours in no-load for loss of the possible damp with the core heating. After
this period it can be put into a normal operation.
 The voltage will be measured at the L.V. terminals to check the

corresponding output voltage depending on the transformation ratio.
 To apply the load progressively until the rated power is reached and check
the increase in temperature.

2.6.16 MAINTENANCE SCHEDULE
Maintenance Schedule:
Equipment Dry Type Transformer
System Voltage 33/0.415 kV
1 Visual inspection of the complete unit for any

abnormality.
Clean any dust from surfaces using a vacuum cleaner
or by blowing with dry air or nitrogen (maximum
pressure 3 Kg/cm2). Nitrogen bottles as normally
supplied, equipped with a pressure reducer, can also
be used.
2 Tightening of bolts & nuts HV/LV of

Incoming/Outgoing cables
3 Tightening of clamps of Aux Box

4 Check the transformer temperature
5 Cleaning of transformer enclosure for dust removal
with a low pressure electric
Blower.
6 IR values:
Quarterly Maintenance Primary winding with 5/2.5 KV megger
P-E = 250 M ohm
P-S = 200 M ohm
Secondary winding with 500 V megger
S-E = 50 M ohm
7 Earthing check for tightness

8 Check the ventilation/cooling of the Transformer
9 Check the control devices such as thermometer temp.
and the monitoring
Units are in working condition. Check the alarm and
trip settings.
Alarm: 90 Deg C
Trip: 120 Deg C
10 Check the tap changer links and tighten them if

required.
The tapping must be same for all the MV coils.

1 All points of quarterly inspection.

Yearly Maintenance
2 Any touchup paints required to be carried out.
Remarks: -
2. Always follow the instruction and Maintenance Manual of the manufacturer.
4. Standard tools and accessories as per Instruction and Maintenance Manuals shall be
5. All Drawings and Manufacture‘s Instruction & Maintenance manual shall be ensured at
2.6.17 Precautions
The following measures are amongst the most important ones.
Before examining or carrying out maintenance on the transformer:
 Disconnect the H.V. and L.V. switches so that the transformer is de-
energized and out of service.
 Using an insulating rod the transformer bushings should be earthed to

ensure that there is no remaining static charge.
 The bushings are then short-circuited and earthed.
2.6.18 Tightening torque of connections
INSTRUCTIONS TO MAKE SCREWED JOINTS IN LOW AND HIGH VOLTAGE
HV & LV SCREWED CONNECTIONS

Indoors Outdoors
Quality of Nuts 8.8 8.8 Stainless Steel A2 or

& Bolts A4
Lubricant for Oil SAE 30 or 40 Molybdenum Bisulphide Grease (Mo S2)
Nut & Bolt Vaseline Grease
Nuts/Bolts Grip Torques (Nm)
M8 10 15 20
M 10 20 30 40
M 12 40 60 75
M 16 80 120 140

When one or both of the bars to be joined together are aluminum, the layer of
aluminum oxide must be removed by brushing or sandpapering. This layer is practically
invisible and extremely resistant, so its presence prevents making a good contact. This
operation must be repeated if the connection bars are dismounted for any reason.
Once clean, apply a very fine coat of special grease for electrical contacts.
Aluminum/copper joints must have a bi-metal plate.
The grip torques, indicated on the table, correspond to greased bolts.
Greasing oil or white Vaseline grease can be used, in order not to soil the area around
the connection.
Molybdenum bisulphide grease must be used for stainless or hot galvanized nuts and
bolts. Any excess must be cleaned after tightening.
HV SCREWED CONNECTIONS
Nuts/Bolts M6 M8 M10 M12 M16
Grip Torques 5 10 20 40 100
(Nm)
H.V. bolts must not be greased because are screwed in brass.

CHAPTER – IV

1.0 THIRD RAIL
1.1 Installation of Brackets
Brackets are differentiated by their height and their base plate.
A) Installation of the brackets for horizontal fixing.
1.1.1 Fix the base plate to the slab. Put the bracket in position to have in alignment the two
holes of the bracket and the two plastic dowels of the sleeper.
1.1.2 Add 2mm HDPE (High-Density Polyethylene) pad between base plate and slab.
1.1.3 For all types of sleeper, the two screws spike are then inserted and pre-bolted. The
torque value must be such as the bracket can manually be moved for adjustments.
Fig. 1.1.1 Concrete Sleeper and Plinth
B) Installation of the brackets for lateral fixing
1.1.4 Put the bracket in position & fix the base plate to the slab.
1.1.5 Put the bracket in position to have in alignment the four holes of the bracket and the
four plastic dowels of the sleeper.
1.1.6 Add 2mm HDPE pad between base plate and slab.
1.1.7 Push 4 screw spikes with double coil spring washers through the base plate in the plastic
dowel of the slab.
1.1.8 The torque value must be such as the bracket can manually be moved for adjustments.

Fig 1.1.2 Bracket Adjustment Positions

1.2 Installation of Insulator
1.2.1 Each mobile jaw is drilled for one fix jaw. Jaws are delivered in assembled condition.
These must be mounted as delivered. These must never be unmatched. Another mobile
jaw cannot be mounted in place of the original mobile jaw delivered with the fix jaw.
1.2.2 Fasten the composite body to bracket by means of one M16x75 screw with flat & spring
washer under its head.
1.2.3 The galvanized brace must be inserted in the brace support and must be inserted then,
from the bottom, inside the top of the bracket. Put the M16 screw going inside the
brace.
1.2.4 Ensure torque value for the bolt must be 80Nm.
Fig 1.2.1: Bracket Insulator
1.2.5 Height of the insulator must be then positioned in reference to the running rail using
Rail setting gauge. This can be achieved by bolting & unbolting the M10 screws
simultaneously or one after the other.
Fig 1.2.2: Height adjustment of Insulator

1.2.6 Check & confirm lateral adjustment( the edge of the bottom of the bracket shall be
strictly perpendicular to the running rail) using Rail setting gauge and bolt the screw
spikes at 200 to 245 Nm for concrete sleeper and plinth.
Fig 1.2.3: Methods of Lateral Adjustment

1.3 Installation of Conductor Rail
1.3.1 Place the rail in correct position of the slot of the fix jaw, one people will introduce the
mobile jaw into the fix jaw. The foot of the rail must be properly set in the slot of the
mobile jaw. Once the mobile jaw is in position, lock it with the two pins.
Fig 1.3.1: Third Rail
1.3.2 This is done with four persons lift the rail at each end while a 5th and a 6th person
assist lifting in the middle, sliding and pushing the rail in such a manner that the base of
the conductor rail will be slotted on the fixed jaw of the insulator.
1.3.3 Be careful and be aware of the ends of the conductor rail which are overhung 2.8
meters, to fit the existing adjoining rails. While the four persons are holding the
conductor rail in position, the 5th and 6th person slides the clamps along the rail web
and tightens the insulator clamp, thereby securing the rail in place.
1.3.4 To ease this procedure, a boom or hydraulic crane with spreader bar could be used. The
ends shall be restrained with properly tied ropes to guide and prevent the section from
spinning, tilting or twisting. A person should guide and act as signalman to forklift or
crane operator and push in conductor base into the fixed jaws of the insulators.
1.3.5 The orientation of the insulator is then checked by means of 5mm thick wedges. On
each side of the fix jaw, one people must check that a 5mm wedge can be inserted
between the top of the rail and the fix jaw.

Fig 1.3.2: Methods of Orientation of Insulator
1.3.6 Check height of the conductor rail using track gauge by means of unbolting insulator
screw and adjusting the height of the insulator by moving up and down using 2 no. M10
screws on the top of the bracket.

Fig 1.3.3: Checking Height of Third Rail using Track Guage

1.3.7 Ensure third rail contact surface should be in the range of -4 to +4 indicated on the
special tool.
1.3.8 Bolt the insulator screw at 80Nm and ensure the two bracket screws for a torque of 200
to 245 Nm with lateral adjustment.
1.3.9 The orientation of the insulator is then again checked by means of 5mm thin wedges.
1.3.10 To cut the rail at right length, use rail cutting band saw and cut must be square at +/-
10.The vertical cut aluminium surface and the contact surface must be abraded and
burrs removed. After the rail is cut it is necessary to drill two holes (16mm dia). Use the
Rail End Drill Jig to do the holes , make sure that template is seated properly at the web
and drill the two holes. Remove the burrs and clean the holes.

1.4 Installation of Splice Assemblies
1.4.1 Apply a thin layer of contact grease after cleaning thoroughly and abrading the surface
of the conductor rail and the splice plates with a steel brush for optimum electrical
conductivity.
1.4.2 Install the splice plates to both sides of the web of the conductor rail end to be joined
keeping a minimum distance of 200mm away from the jaws of the closest insulator.
1.4.3 Tighten the outer two Huckbolts, make sure that the rail ends are touching each other
and then install the rest two Huckbolts. Use appropriate equipment for installation of
Huckbolts.
Fig 1.4.1: Splice Assemblies

1.4.4 Clean the joint of any excess contact grease and securely cover the contact grease
container to prevent any contamination. Put corrosion resisting paint on broken side of
each Huckbolts.
1.4.5 Lightly polish (with an emery disc) the stainless steel surfaces at the rail junction to
obtain a smooth transition between the two conductor rails.
1.4.6 Ensure that all the Huckbolts and collars dismounted must be replaced and never be
used again.
1.4.7 The maximum gap between the two conductor rail shall be 2mm.

1.5 Installation of Expansion Joints
1.5.1 Bring the expansion joint assembly to the vicinity of the installed insulator chairs.
1.5.2 Extreme caution must be exercised in lifting the assembly.
1.5.3 Two persons should be able to lift the assembly while the third person assists lifting near
the middle, sliding and pushing the rail in such a manner that the base of the conductor
rail of the assembly will be slotted on the fix jaws of the two insulators. Be careful and
be aware of the ends of the adjoining installed conductor rails.
1.5.5 Ensure the length between the expansion joint and insulator will be the same on the two
sides.
1.5.6 Check the height and the alignment of the expansion section assembly using track
gauge, adjust if needed.
1.5.7 Record and take the average of the temperature with the sensor point at base, at
bottom web and top surface of the conductor rail using digital thermometer.
1.5.8 Set the right gap opening of the expansion joint by sliding on end of the expansion joint
with adjustable screw by using table below which is arrived through the calculation note.

Fig 1.5.1: Expansion Joint Gap
CR Temp in 0
CR Temp in 0 Gap CR Temp in 0 Gap Gap
C at the time
C at the time in C at the time in in
of
of Installation mm of Installation mm mm
Installation
6 149 19 125 32 100

7 147 20 123 33 98
8 146 21 121 34 96
9 144 22 119 35 95
10 142 23 117 36 93
11 140 24 115 37 91
12 138 25 113 38 89
13 136 26 112 39 87
14 134 27 110 40 85
15 132 28 108 41 83
16 130 29 106 42 81
17 129 30 104 43 79
18 127 31 102 44 77

1.5.9 Recheck the contact surface alignment and temperature readings.
1.5.10 For installing of expansion joint, start from one anchor, install the expansion joint at half
of the recommended distance and go to the second anchor at the other side of the
expansion joint to install the rest of the third rail. Then remove the expansion joint
special tool.
1.5.11 The installation of the two anchors and the adjustment of the expansion gap must be
made at the same time of the day to get constant ambient temperature.
1.5.12 Power feed cannot be installed on the 4m long expansion joint section.
1.5.13 The brackets on either side of the expansion joint assembly should be marked by red
paint to ease the maintenance control.
1.5.14 Expansion sections are not desirable in radii under 300mtrs and it is not recommended
to avoid installation of an expansion on a curve. However, if it is unavoidable, then the
radii in any case should not be less than 300 m.
1.5.15 After the expansion section installed protective cover must be specially cut near the
expansion joint with the formula RFIX = 0.5 X GAP + 80 in mm & RMOBILE = -0.5 X
GAP + 180 in mm
1.5.16 Fasten the two upper and the four lateral cover fasteners for expansion joint with CHC
screws M8x35 (8 Nm) and put on the expansion joint cover. Put the 4 plastic washers in
the holes of the expansion joint cover and fasten it with 4 slotted flat head screw M8x25
(2 Nm) in the cover fasteners of the expansion joint.

Fig 1.5.2: Expansion Joint Assembly

Fig 1.5.3: Expansion Joint Covers

1.6 Installation of Anchor Blocks
1.6.1 Installation of the anchor assembly can be done after the conductor rail had been
installed from end to end. Go to expansion section, check gap setting as per chart
before drilling second anchor in place.
Fig 1.6.1: Anchor Blocks

1.6.2 Identify the location where the anchor blocks to be installed, locate the nearest insulator
bracket.
1.6.3 Ensure the clearance between the edges of the jaw to the edge of the anchor block is
less than 3mm.
1.6.4 Drill a 13mm dia hole on each side of the insulator jaws using the mid anchor rail drill jig
ensuring rails are secured and the insulator support bolts are tightened properly so that
it will not topple over.
1.6.5 Apply a thin layer of contact grease on the contacting surface of the conductor rail and
the anchor blocks for optimum electrical conductivity.
1.6.6 Install and fit the anchor blocks on both sides of the insulator jaws and tighten with two
Huckbolts using the prescribed equipment.
Fig 1.6.2: Installation of Anchor Blocks

1.6.7 Clean the joint of any excess contact grease and securely cover the contact grease
container to prevent any contamination. Put corrosion resisting paint on broken side of
each Huckbolts.
1.6.8 Two anchor sets must be installed on two consecutive insulators for every length of rail
up to 90 meters.

1.6.9 The bracket on which the anchor assembly is mounted should be marked by red paint.
1.6.10 Ensure that all the Huckbolts and collars dismounted must be replaced and never be
used again.

1.7 Installation of Cover Fasteners ( Clips)
1.7.1 Descend the cover fastener up to the top horizontal surface of the conductor rail till the
foot of the rail comes in contact with the internal surface of the cover fastener.
1.7.2 The two teeth of the cover fastener must then be under the level of the foot of the rail.
1.7.3 The cover fastener is then turned by 300, check the teeth are correctly in position under
the foot of the rail. If necessary use a soft hammer to put the cover fastener at the right
position and to block it on the foot of the conductor rail.

1.7.4 Cover fasteners must be set every 420mm maximum i.e 12 cover fasteners between two
insulators.
1.7.5 Minimum distance between the conductor rail clamp and the closest part of the cover
fastener is 200mm.

1.8 Installation of Ramps
1.8.1 Identify the location where the ramps to be installed, locate the nearest insulator
bracket.
1.8.2 Locate the three insulators and check the dimensions from right end of the ramp (bent
side) to insulator, insulator to insulator and left end of ramp (splice side) to insulator.
The dimensions should be as specified in the drawings.
1.8.3 Install ramp by slotting its base in to the jaws of the insulators. Secure the ramp by
tightening the jaws hardware while one person holds the ramp to prevent the assembly
from tilting.
1.8.4 Slide the adjoining conductor rail to be spliced to the butt of the ramp.
1.8.5 Set the height of the ramp using the Rail Track Gauge in regards to the height of the
ramp as per drawing.
Conductor rail contact surface height should be in the range of ±4mm.
1.8.6 Splice the ramp as explained in installation of splice assemblies.
1.8.7 Ramp cover must be cut to the correct length to join the insulator cover of the second
bracket and have a minimum recovery distance of 100mm.
1.8.8 Ramp cover must be cut in a specific manner in the area of the first bracket for the
insulator using the ramp cover cutting jig. The opening has to be marked on the cover
by using the mask. The mask is removed and the opening is made with a plastic saw.

1.8.9 Two lengths of the standard protective cover have to be adjusted and joined by a
specific cover with 8 Nos. M5 plastic screws near from the first bending axis of the ramp
i.e. at 550mm from the end of the ramp-spliced side.
1.8.10 Put the specific cover on the two other standard covers and drill the two standard
covers using the drilling of the specific cover.
1.8.11 Ensure minimum recovery of 100mm at cover junctions.

1.8.12 The cover fasteners of the end of the ramp need to be modified to respect the structure
gauge. It‘s necessary to cut the cover fasteners at the correct height to get the ramp
cover horizontally at the end of the ramp. The cutting profile should be the same as the
top of a complete cover fastener.

1.8.13 Installation of special cover fasteners should respect the rules explained in cover
fasteners installation.
Fig 1.8.1: Ramp Assembly

1.9 Installation of Connector Plates, Power feed
1.9.1 Locate the point where the power feed is to be installed and identify the no. of
Assemblies.
1.9.2 Drill the three 16mm holes using the power feed rail drill jig , remove the burrs, clean
the holes, and clean the area of any debris.
1.9.3 Apply a thin layer of contact grease after cleaning thoroughly and abrading both the
sides of web of the conductor rail and the connector plates with a steel brush for
optimum electrical conductivity.
1.9.4 Install the connector plates to both sides of the web of the conductor rail ends. Tighten
the outer two Huckbolts, make sure that the collar shall be at the opposite side of the
cables lugs bolting area and then install the last Huckbolts.
1.9.5 Clean the area of any excess contact grease .Put corrosion resisting paint on broken side
of each Huckbolts.
1.9.6 Put the bimetallic plate between lugs and power feed and set the contact grease for
mating between the two surfaces.
1.9.7 Cut the cover at the location of the power feed using power feed cutting mask designed
for the protective cover. Put the jig at the right position on the protective cover and cut
the cover following the jig.

1.9.8 Drill the four 8mm Dia holes, fasten the cover fasteners for power feed on the plate with
4 CHC screw M6x40 at 9Nm, 4 flat washers, 4 helical spring lock washers and nuts M6.
1.9.9 Put the special cover on the power feed and fastened it by four plastic screws, washers
and nuts to the protective cover through the 8mm holes drilled previously.
1.9.10 Ensure a minimum distance of 500mm between two power feed covers and edge of the
power feed must be at least 1 meter away from the closest insulator‘s jaw.
1.9.11 Each power feed assembly can accommodate two 500 sq. mm copper cables and not
more than 3 power feeds installed between two brackets.
1.9.12 Ensure no power feed to be installed on the expansion section.

1.10 Installation of Insulated Joint Assemblies
1.10.1 Bring the insulated joint assembly to the vicinity of the installed insulator chairs.
1.10.2 Extreme caution must be exercised in lifting the assembly.
1.10.3 Two persons should be able to lift the assembly while the third person assists lifting near
the middle, sliding and pushing the rail in such a manner that the base of the conductor
rail of the assembly will be slotted on the fix jaws of the two insulators. Be careful and
be aware of the ends of the adjoining installed conductor rails.
1.10.5 Ensure the length between the insulated joint and insulator will be the same on the two
sides.
1.10.6 Check the height and the alignment of the insulated section assembly using track gauge,
adjust if needed.
1.10.7 The brackets on the either side of the insulted joint assembly should be marked by red
painted to ease the maintenance control.
1.10.8 Insulated sections are not desirable in radii under 300mtrs and it is not recommended to
install an insulated joint on a curve.
1.10.9 Standard protective cover must be put on the insulated joint. Two cover fasteners
should be put to the closest of the ends of the insulated joint splices. Three other cover
fasteners should be cut and put on the insulated joint. Screws should be between the
legs of 3 these cover fasteners.

1.10.10 Clip the protective cover on the insulated joint pushing on the top of the cover at
the position of the two nearest cover fasteners.

1.11 Installation of UPVC & GRP Protective Covers

1.11.1 Before installation of covers, make sure that the conductor rail components are rightly
installed.
1.11.2 Cover (4.850mtr) must be presented in a vertical position, opening down with each end
of cover must be located at an equal distance from the closest insulator.
1.11.3 In case the length between consecutive insulators is less than 5mtr , it is necessary to
cut the cover at the adequate length L=E-150(in mm) where E stands for the length
between the insulators.
1.11.4 The accuracy of cut must be [0,-10mm] and cutting of the cover must be square to the
cover axle with an accuracy of [-2, +2] and debur the ends.
1.11.5 The cover is clipped on the cover fasteners by pressing on the top of the cover. Clip one
of the legs of the cover correctly on the cover fastener and push on the top of the cover
at the position of the cover fasteners to clip the other leg.
Fig 1.11.1: Protective Cover

1.11.6 The bottom of the cover must be around 20mm above the contact surface.
1.11.7 Correct mounting of the cover must be checked by means of 20mm thick wedge applied
at the bottom of the rail and verifying the bottom of the wedge is at the same level than
the contact surface of the rail. Mirror can also be used to check the cover is correctly
clipped on the cover fastener.
1.11.8 On ramps the cover must be cut in such a manner to let the space required for the
passage of the insulator.
1.11.9 Take special care when installing UPVC covers radii less than 94mtr.

1.12 Installation of UPVC & GRP Insulator Covers
1.12.1 At the location of the insulator, the standard cover is interrupted and the insulator cover
is used to against the conductor rail under tension.
1.12.2 Insert the leg of the insulator cover located against the insulator by increasing the
opening of the cover by spreading the legs of the insulator cover.
1.12.3 Take special care not to go beyond the elasticity and not to crack or break the insulator
cap.
1.12.4 The leg of the adjacent covers must be inserted both side inside the bent end of the leg
of the insulator cap. This operation can be facilitated in pressing the insulator cap
against the insulator and rising slowly the leg of the adjacent covers.
1.12.5 Press on the top of the insulator cover to clip the second leg.
Fig 1.12.1: Insulator Covers
1.12.6 When the covers are rightly installed, the warning label shall be put on.

1.13 Structure Dimensions Control
1.13.1 At the end of the conductor rail installation, check the conductor rail system dimensions
to ensure the installation is not out of the structure gauge using structure gauge which
represents the maximum authorized dimensions of the conductor rail system.

2.0 MAINTENANCE OF THIRD RAIL
2.0.1 GENERAL
2.0.1.1 The maintenance of the Power Rail Conductor System must be carefully planned and
executed so that the system will achieve its highest performance at the most economical
cost. The rail conductor maintenance should be a part of the end-user overall system
maintenance program.
2.0.1.2 This maintenance program is a recommended procedure and formulated in the premise
that the system components are installed properly to the specifications of the Power Rail
conductor System Installation.
2.0.1.3 DESIGN DATA
a) Electrical
_ Nominal voltage: 750 V.
_ Nominal amperage: 4,000 A.
_ System resistance: inferior to 7 mW/m
b) Geometrical
_ Distance of contact surface above running rail: 200 mm
_ Horizontal distance of middle contact surface to track axis: 1 402 mm
_ Contact surface horizontal adjustment (via oblong holes): 50 mm
_ Contact surface vertical adjustment (via an oblong hole): 100 mm
_ Distance between supports: 5 m max.
_ Contact surface width: 75 mm
_ Rail height: 105 mm
_ Ramp pick up height: 96 mm
c) Mechanical
_ Weight of rail: 17 kg/m
_ Admissible load on rail at mid span: 1500 N
d) Thermal
Maximum rail heat rise at 4,000A and 40°C external: 45°C above ambient

2.0.2 TROUBLESHOOTING
2.0.2.1 Conductor Rails

Sl. Trouble Probable Possible Remedy
No. Cause
1.
Overheating: Loose Splice Rectify by disassembling the splice assembly.
If overheating has occurred,
there is high possibility that Assembly Clean and wire-brush the mating surfaces.
arcing or burning has (Connection
damaged some or all between rails) Thoroughly inspect all components for arcing damage, if
components in the vicinity. none is found, apply.
Specific remedial repairs will Contactal grease on the mating surfaces and abrade with
depend on the extent on the a wire brush.
damage. Assemble the splice assembly with four Huck Bolts.
Overloading Check the electrical loading by doing a load survey.

Rectify if not according to system parameters.
Loose Power Rectify, by disassembling, cleaning, applying Contactal grease
feed on the mating surface and set the three Huck bolts.
(Connector
Plates)
2.
Distortion Accidental Upto a distortion of 3 mm the rail should be replaced or cut to
Vertical or/and horizontal change the deficient part at the first opportunity.
buckling of the third rail Impact
system.
Buckling The anchor assemblies and the expansion joint
(around the deficient part) should be inspected in order to
rectify.
3.
Uneven wearing Misalignment Check the conductor rail contact surface plane with the special
Of the conductor bar stainless of conductor tools (running rail as reference – Rail Track Guage). The
steel contact surface. rails with horizontal distance of the contact rail center should be
respect to the
collector shoe 1480 mm from the track axis.
operating Adjust the level of the insulators near the rails affected. If
plane the angle between contact surface and collector shoe is
envelope. not plane, the surfaces in contact will be significantly
reduced and localized heating resulting in electrical
erosion can be experienced.
Check insulator surface. If damage, change the insulator
support.
Check insulator mounting hardware for looseness.
Rectify and re-torque to the specific torque.

4.
Micro-arcing Loose splice Rectify by disassembling, cleaning and then applying
At the conductor butted ends
of the splice joints. Assembly Contactal grease on the mating surface.
Set the four Huckbolts.
hardwares
2.0.2.2 Splice Assemblies

No. Cause
1. Overheating Loose Splice Open up the assembly and clean and abrade the mating
If overheating has occurred, Assembly surfaces with a wire brush.
there is high possibility that (Connection Coat the mating surfaces of the splice plates and the rail
arcing or burning has between rails) with Contactal grease.
damaged some or all Assemble the plates and Huck bolts. Use anti-seize
components in the vicinity. lubricant to prevent stainless steel from galling.
Specific remedial repairs will
depend on the extent on the
damage.
2.0.2.3 Expansion Section

No. Cause
1. Overheating Loose Splice Rectify by re-installing the splice assembly.
If overheating has occurred, Assembly
there is high possibility that (Connection
arcing or burning has between rails)
damaged some or all Bad contact Dismount the copper shunts.
components in the vicinity. Clean and abrade the mating surfaces.
Specific remedial repairs will Coat the mating surfaces of the splice plates and the rail
depend on the extent on the with Contactal grease and bolt the two shunts.
damage. Overloading Check loading by load survey. Rectify if not according to
design.
2. Uneven wearing Misalignment Check the expansion conductor rail sections contact
Of the stainless steel contact of conductor surface plane with the special tools (running rail as
cap. With respect reference—Rail track guage).
to the
collector shoe The horizontal distance of the contact rail center should be
operating
1480 mm from the track axis.
plane
Adjust the level of the insulators near the rails affected. If
envelope.
the angle between contact surface and collector shoe is
not plane, the surfaces in contact will be significantly
reduced and localized heating resulting in electrical
erosion can be experienced.

Check the insulator mounting hardware to the bracket for

looseness.
3. Micro-arcing Loose splice Rectify by re-installing the splice assembly.
At the conductor butted ends assembly Clean and coat the mating surfaces with Contactal grease
of the splice joints. (connection and abrade with wire brush.
between rails)
2.0.2.4 Ramp
Sl. Trouble Probable Cause Possible Remedy

No.
1. Excessive Arcing Vibration Check the base plate of the insulator mounting screw
At the Conductor Spikes. Tighten according to the correct torque value.
Check the insulator mounting bolt. Rectify by tightening the
bolts according to the specified torque.
Loose jumper Rectify by cleaning the Contactal surfaces, apply
cables Contactal grease and tighten the hardware to specified
torque values.

2.0.3 INSPECTION AND MAINTENANCE SCHEDULE
2.0.3.1 Conductor Rails

Sl. No. Inspection Procedure Interval or Frequency
1. Overheating to check the abnormal discoloration of the Weekly in a rotating basis to cover the total length
aluminium or the stainless steel contact surface. of the guideway on three months.
2. Uneven wearing of conductor stainless steel contact. Basis: During the first year of operation. After the
3. Micro-arcing at the conductor ends. first year, inspection interval could be adjusted
4. Distortion of the conductor rail system. based on history of the system.
5. Infrared inspection—During the inspection using Infrared scanner should be used as required when
non-contact infrared devices, the conductor rails must loose connections are suspected.
have current running for at least 30 mins. After it is
recommended to switch off the section where
inspection has to be performed and to use the short
circuit device.
6. Overheating can be identified by infrared scan when a
portion of the stainless steel contact cap temperature
exceeds the adjacent conductor rail contact surface
temperatures by at least 10 deg C.
2.0.3.2 Splice Assembly

Sl. Inspection Procedure Interval or Frequency
No.
1. Overheating to check the abnormal discolouration of Weekly in a rotating basis to cover the total
the aluminium body, and the stainless steel contact length of the guideway on three months.
surfaces of the joint. Basis: During the first year of operation.
2. Check for loose splice hardware by performing random After the first year, inspection interval could be
verification (this must be done during the non-revenue adjusted based on history of the system.
period).
3. Infrared inspection, during inspection using non- Infrared scanner should be used as required
contact infrared devices, the conductor rails must have when loose connections are suspected.
current running for at least 30 mins. After it is
recommended to switch off the section where
inspection has to be performed and to use the short
circuit device.
4. Overheating can be identified by infrared scan when
an adjoining conductor rail end of the splice assembly
or the splice plate temperature exceeds the adjacent
conductor rail end temperatures by at least 10 deg C.

2.0.3.3 Expansion Section

No.
1. Overheating to check the abnormal discolouration of Weekly in a rotating basis to cover the total
the aluminium body, stainless steel contact surfaces length of the guideway on three months.
and the copper laminated jumper conductors. Basis: During the first year of operation.
2. Uneven wearing of conductor stainless steel contact After the first year, inspection interval could
can be identified by chatter marks where the collector be adjusted based on history of the system.
shoes are skipping.
3. Micro-arcing at the conductor ends.
Check all components in contact with the collector
shoes for sign of wear.
4. Infrared inspection— the following observations, Infrared scanner should be used as required
including but not limited, shall be made during the when loose connections are suspected.
maintenance inspections.
5. Overheating can be identified when the splice
connections or the copper bar (at the expansion
sections) exceeds the adjacent conductor rails by at
least 10 deg C.
6. Long Term Work Every 5 years, the expansion joints shall be
dismounted to check the splices, change the
Contactal grease, and be examined in totality.
2.0.3.4 Anchor Assembly

No.
1. Check if each half anchor is in correct position around Weekly in a rotating basis to cover the total
the dedicated insulator jaws. length of the guideway on three months.
2. Check the bracket alignment with the running rail. Basis: During the first year of operation.
Check the tightness of the base plate mounting bolts. After the first year, inspection interval could
3. Check hardware for their correct torque values and be adjusted based on history of the system.
shown in correct places as per location drawing.

2.0.3.5 Insulator Support

No.
1. Check the insulator mounting screw spike, spring Weekly in a rotating basis to cover the total
washers and all elements of the insulator assembly are length of the guideway on three months.
present. Basis: During the first year of operation.
2. Check the clamp. After the first year, inspection interval could
be adjusted based on history of the system.
2.0.3.6 Power Feed

No.
1. Visually check for any discoloration of surfaces around Weekly in a rotating basis to cover the total
the area where the power feed plate is connected to length of the guideway on three months.
the base of the conductor rails. Basis: During the first year of operation.
Discoloration of the surfaces can indicate loose cable After the first year, inspection interval could
lug terminations or power feed bolts. be adjusted based on history of the system.
2. Check the lay of the power feed cables. The power conductor
rail movement must not be restricted during the changes of
rail temperature due to changes in ambient temperature
and/or electrical loading.
3. Check the shrink on bolts for any breaks or deterioration.
2.0.3.7 Cover System

No.
1. Inspect the cover system. There shall be no loose and Weekly in a rotating basis to cover the total
no displacement causing a danger – Change if length of the guideway on three months.
necessary. Basis: During the first year of operation.
2. After the first year, inspection interval could
Inspect the surfaces of the covers. There shall be no cracks
and no delamination causing danger – Change if be adjusted based on history of the system.
necessary.

2.0.3.8 Conductor Rail System Cleaning

No.
1. Inspect the conductor and insulator for a white powder Check weekly around the vehicle wash area. Clean
build-up. This powder may provide an electrical path as required.
to ground. Remove the powder by washing with
distilled water then drying with compressed air.
2. Inspect the conductor for filling accumulation caused Inspect weekly in a rotating basis to cover the total
by rail grinding. Contaminants on the web of the length of the guideway on three months.
conductor will be removed through normal oxidation, Basis: During the first year of operation.
although, a discoloration of the bar will occur. If After the first year, inspection interval could
excessive, the contaminants need to be removed. be adjusted based on history of the system.
Clean the web with compressed air at time of rail Clean at rail grinding and as required.
grinding.
3. Inspect the insulator support for iron filling Yearly systematic washing.
accumulation, iron flings may grind the insulator
material. Remove any iron flings using compressed air
and/or spraying distilled water then drying with
compressed air. Iron flings accumulating on the
insulator may create a path between positive and
negative rails or to the pedestal base. If electrical
arcing is evident, replace the insulator.
Inspect expansion sections for iron filling accumulation. Iron
flings may denigrate performance. Remove any iron
flings using compressed air. Clean insulator composite
body with tap water under pressure then dry with
compressed air and wait one hour before setting
voltage. There is no need to dismount protective
covers.

CHAPTER – V

SCADA
(Supervisory Control & Data Acquisition System)

1.1 Basic Operation
1.1.1 Start of WS500

WS500 is started from the Start menu in a Microsoft Windows PC.
Login
When WS500 is started, it is required to log in with a SCADA operator user name and
password.
Picture call up
A default picture is automatically presented after login. From that, navigation can be
performed to other pictures.
1.1.2 The graphical user interface
Fig. 1.1.1: WS 5000 Graphical User Interface

1.1.2.1 The graphical interface consists of a Microsoft Windows styled application window.
A menu, toolbars and an area for picture presentation can be found in the application.
Up to 4 pictures can be presented in one WS500.
1.1.2.2 Process information is presented in process pictures and in lists. Dialogues are selected
from menus and performed with the help of dialog boxes. Both pictures and dialogues
can be selected by shortcuts; a combination of keys on the keyboard and/or the mouse.
1.1.2.3 Menu bar picture call up

The menu bar contains selections for both program functions and for picture
presentation. The normal usage of the menu bar picture navigation is for subsystem
overview picture presentation.
1.1.2.4 The Toolbar

The toolbar is used for frequently used functions and are represented by an icon. The
tooltip function presents a textual explanation of the icon.
1.1.2.5 Poke points

Poke points (push buttons) are presented within pictures using a text or icon and can be
used for picture call up, for program start, and function start up.
Fig 1.1.2: Examples of Poke Points

1.1.2.6 Dynamic Function Keys (DF-keys)

Each picture in the system has 10 Dynamic Function Keys (DFKs or Soft keys).
DFKs can be used for picture call up, for program start, and function start up.
1.1.2.7 Using the right click popup menu

A two-button mouse is used to operate the cursor. With Mouse Button 1 (MB1) functions
and objects can be selected. Pressing MB2 presents a pop-up menu.
The possible selectable items in the pop-up depend upon the type of object selected
when MB2 is pressed.
1.1.3 Using the mouse to Zoom and Pan

Zoom is easiest performed by pressing MB1 and while MB1 is pressed, moving the
cursor. The new-presented area of the picture will be the rectangle, created by the
mouse movement.
The zoom-functions are used to enlarge and reduce the size of the information of the
pictures. More information may also be added to the Declutter levels (DCL). "Zoom in"
will then give an "Information zooming", providing this function has been selected
during picture engineering. Information zooming can also be performed in steps using
the Up and Down Declutter functions.
Zoom Home will return the picture to the zoom and Declutter level it had when it was
originally selected. Using the Zoom Area function, the selected part of a picture will
proportionally be enlarged to the window size. The Zoom back and Zoom forward
functions save the previous zoomed in area, Declutter and layer settings.
Pan is made in a zoomed display, either by pressing MB2 and dragging the cursor when
MB2 still is pressed, or by using the vertical and horizontal scrollbars.
Panning can also be done by pressing MB1 + Ctrl + Shift, but then the area of the
picture should be clicked that is to be focused upon.
1.1.4 Locate
The Locate function enables the location of network components within graphical
pictures. The identity of the network component to be located can be entered manually
in the selection field or selected from pictures. The object can also be picked from the
list in the dialog box after a filter action has been performed.

Fig 1.1.3: Locate Dialogue Box
1.1.5 Getting more object information from a process picture
Pointing at a picture element, using the cursor and pressing MB1 select an object.
Pressing MB2 makes retrieving detail information for this object and then selecting info
in the popup menu while the picture element still is selected. In the dialogue that is
displayed, the identity of the network component (object name) has to be entered
manually.
Fig 1.1.4: Info Dialogue Box

1.1.6 The Alarm Window
The five latest incoming unacknowledged alarms for total SCADA are presented in a
special Alarm Window. An Alarm button to the left in the Toolbar indicates by a red color
the presence of an unacknowledged alarm. Click on the button to open the Alarm
Window.
The Locate function can be used to quickly select a station or overview picture showing
the object in alarm.
Fig 1.1.5: Alarm Window
1.1.7 Audible alarm reset
The audible alarm is stopped by pressing the button labeled with a deleted horn icon in
the Toolbar next to the Alarm icon.
Fig 1.1.6: Stop Audible Alarm

1.1.8 Alarm, Event and Sequence of Event Lists
There are a number of lists with event and alarm messages:

• Alarm list.
• Event list.
• Sequence of Event List (SOE), containing status changes of breakers, start/stop and
trip signals from overload relays and messages from disturbance analyzers.
If only events or alarms from the actually selected Station, Subsystem and System are
required, select the station picture before selecting the Event, the SOE or the Alarm lists.
1.1.8.1 Event List
The event list is circular and contains a number of messages, e.g., 20000. A new
message replaces the oldest message in the list. When an Event list is selected for
presentation, the last page is presented only half filled, to make room for additional
events without scrolling.
Navigation by selecting Top, Bottom, Page up, Page down, scroll up (3 lines) and scroll
down (3 lines) as well as time selection can be performed in lists. Navigation is also
possible by using the internal scroll bar of the list.
An extract of events, e.g., from a certain station, may be made if the station is selected
prior to the selection of the Event list.
In the parameter field to the right of the list, the following letters may occur:
L -- Digital relay; event caused by local operation

M -- Event precipitated by manual action
S -- Event noticed by the Standby server
P -- Event initiating a disturbance recording
1.1.8.2 Alarm List
The alarm list contains unacknowledged and persistent alarms. Unlike the event list, the
alarm list is not circular in that it may be topped up with new alarms. The alarm list
contains a number of messages. When the warning "Alarm list full" is obtained, the
alarms should be acknowledged.
When the Alarm List is selected, the first page is presented. A selection of alarms may
be made by pre-selection of, for example, a station. A DFK Extract is also available. The
same keys are used for scrolling and paging as in the Event List.
The letters in the parameter field to the right of the list are as follows:
M -- Alarm precipitated by manual action

S -- Alarm noticed by the standby server

P -- Alarm initiating a disturbance recording

Messages marked with a * are unacknowledged.
The following colors are used:
Green the message disappears after acknowledgment

Yellow the message remains after acknowledgment.
1.1.8.3 SOE/Sequence of Events
The Sequence of Events List contains messages from the process with a more accurate
time tagging than the event list. Only signals collected by special process communication
terminals have this possibility. The time tagging is carried out in the RTU.
Depending on the accuracy of the time stamp the seconds can be presented with one,
two or three decimals.
1.1.9 Creating, changing and navigating in trend curves
Trend curve presentation is used for presentation of the history of analog values.
Trend pictures are selected in the same way as process pictures using menu, toolbar,
DFK and poke point selections.
1.1.10 Creating, changing and navigating in reports
Tabular displays can be used for presenting data in tabular form. Tabular pictures are
selected in the same way as process pictures using menu, toolbar,
DFK and poke point selections. The numeric data can be presented in numerical tabular
and different graph formats such as histogram, pie, scatter plot etc.

1.2 Control of Objects
1.2.1 Basic Authority concept
The authority assignment is carried out in the context of the Operator's login.
For each operator account, a specific authority for actions and/or picture selection in the
power and control systems is defined.
1.2.2 To Open and Close Breakers
Selecting a picture element representing the object to control and then selecting
command, issue a command. The command is then issued from the dialog box that
appears.
The prerequisites for on/off or continuous control commands are:
• The workplace is connected to the on-line application server.

• Authority for the action has been established.
• Remote control is not blocked.
• The object is not controlled from any other workplace.
• The object is not waiting for the response to a previously entered command.
• The object is marked as updated.
• The object is not marked as update blocked.
• Contact has been established with the remote terminal unit concerned.
• Any Interlock rules for the object are fulfilled, if defined.
If any of these prerequisites is not met, a message explaining the situation is output. An
alarm is also issued on a command sequence error. An object selection, which is not
allowed, results in one error message in the error message box and one in the Event list.
If no command acknowledgment has been returned within a certain time, an alarm is
issued. The color for 'pending command' is displayed.
A comment can be made in the dialog box. It is shown when the dialog box is presented
again and in the information-picture for that object.
The dialog is also used to switchover between Auto and Manual control modes of
regulatory objects.
There are default interlock checks that can be used with the command dialogue.

These default interlock checks include the following three checks:
• Connecting grounded and energized devices

• Connecting two network groups
• Opening critical path, where at least one load will be de-energized
• Closing network loops
In addition there can be other default interlock rules associated with tags.
Fig 1.2.1: Command Dialogue Box
1.2.2.1 Interlock rules: Bypass
If the Interlock rules for an object are not fulfilled the bypass function can be used
under special circumstances.

1.2.3 Manual Data Entry
By selecting the Data Entry alternative, a dialog is started to manually enter a new value
of the selected status indicator/analog value/text or time.
Manual data entries are logged in the event list, together with the initiating operator
name.
In the pictures, points with manually entered values are marked in cyan (light blue).
Manually entered values are processed in the same way as ones acquired from the
process or the control system. This means that the event handling works as normal.
The prerequisite for a status change on/off by manual data entry is that any Interlock
rules for the object are fulfilled, if defined. If these prerequisites are not met, a message
explaining the situation is output.
A comment can be made in the dialog box. It is shown when the dialog box is presented
again and in the information picture for the object.
There are default interlock checks that can be used with manual data entry.
These default interlock checks include the following three checks:
• Connecting grounded and energized devices (Can NOT be bypassed)

• Connecting two network groups (Can be bypassed)
• Opening critical path, where at least one load will be de-energized (Can be bypassed)
• Closing network loops
Fig 1.2.2: Data entry dialogue box for Object Status

1.2.4 Tagging
A tag is a method of bringing to the attention of other operators and the system itself
that an object currently has a special status e.g. section under test. This may relate to
work in progress or other abnormal conditions in the process.
A number of tags can be set for the same object but only the tag with the highest
priority will be displayed.
Each operator, who has control authority for an object also, has the authority to set and
remove tags for that object. Tags can be set for the following types of objects: objects
represented as indications, transmission lines and stations.
When a tag is issued for an object, the date, time, operator identity, job identity,
worker's name and a comment text can be entered. An interlock can reject the issue of
a tag.
Fig 1.2.3: Tagging Dialogue Box
Tag information is presented in the following ways:
a) In single-line diagrams, in the position specified during picture editing

b) In dedicated lists showing all tags currently defined
c) In the event list, where setting and removing of tags is recorded.

1.3 Limit Supervision
1.3.1 Using Alarm Limits
Alarm limits are set and changed using the Limit dialog.
Fig 1.3.1: Limit Dialog Box
Change of limits used for supervision of measured values can be made if the workplace
has the authority to do so. A plausibility check is performed on the new limit values, i.e.
is the value within the measuring range of the transmitter, is the limit values correctly
related to each other etc.
A limit transition results after a dead band filter in an alarm state for the object.

1.4 Control system
A faulty unit may be taken out of service until the fault is corrected. This may not
necessarily mean that a function using the unit is notified thereof. For this reason,
taking a unit out of service often has to be accompanied by re-allocation of the input or
output concerned.
Printers and Remote Terminal Units can be switched in and out of service. If an RTU is
taken out of service, the data acquisition from it is suspended and the signals concerned
are marked as not updated in the central database. The change is logged in the event
list of the control system.
Printers can also be taken in and out of service. The change is logged in the event list of
the control system.
1.4.1 Application Servers
Overview pictures as well as individual Info-pictures for each application server are
available.
The Info pictures are used for Manual switchover and stop/start of servers.
Note: An application server has to be stopped before it can be restarted.
1.4.2 Operator Workplaces
Operator workplaces can be taken in and out of service in the control system overview
picture from another workplace with authority to take control system units in and out of
service.
1.4.3 Printers and Hardcopies
A unit number can be assigned to each type of printout. Note that when the unit
number is changed, all reports of this type are re-routed to the new printer specified.
The printers have a backup device. In case of failure, this unit becomes the printout
unit.
1.4.4 RTU-s (line units, com ports)
The Process Communication Unit device, PCU, represents one H/w unit that contains
physical communication lines connecting the RTUs. The PCU1501 picture displays any
status and controlling capabilities for one PCU.
The COM line device represents one or several physical lines that can be used to
connect RTUs. The COLI1501 picture displays any status and controlling capabilities for
one COM line.
The Remote Terminal Unit, RTU, connects the process with the SCADA system.

The RTU1501 picture displays any status, controlling and supervision of one RTU.
The Line Unit device represents one physical line either single or redundant. The
LINU1501 picture displays any status, controlling and supervision of one Line Unit.
1.5 MAINTENANCE SCHEDULE OF RTU

Equipment RTU
1 Visual inspection of LED status of CPU card, Power

supply card, DI card, DO card, AI card and power
supply card.
2 Check the configuration of RTU rack and error log
through RTU diagnostic tool by Laptop.
3 Take the back up of RTU files through the RTU
configuration tool by Laptop.
4 Check the voltage at every DI-TB and DO-TB
5 Check the working and performance of power supply
units and communication convertors
6 Cleaning of RTU panel using vacuum cleaner
Quarterly Maintenance 7 Check the tightness of all cable terminations at the
RTU panel
8 Checking of Interposing relay, tightness of cable
terminations, relay markings.
9 Checking the auto change-over function of L.T.
breakers through SCADA
10 Check the earthing connections and seal the holes, if
any.
Check the working of heater and lightning
arrangement inside the RTU
Check the functioning of Local SCADA permissive of
circuit breaker isolator, interrupters and BMs
1 Check close/open operations and SCADA permissive of
circuit breaker, isolator, interrupters and BMs
Yearly Maintenance 2 Check indications and alarms of sub-station
equipments in SCADA along with PSI team at the time
at the time of CB maintenance.
Remarks:
1. Always follow the instruction & maintenance manual of the manufacturer.

2. All safety precautions shall be taken during maintenance.
3. All drawings and manufacturer‘s instruction & maintenance manual shall be
ensured at site for reference during maintenance.

1.6 Glossary and Abbreviations

1.6.1 Glossary
Application server -- Application Servers are those servers that perform functions
without direct dual communication except via the LAN. Single or double computers can
build up each Application Server. The number of servers that are needed depends on
the total functionality of the installation and the performance and availability
requirements imposed with this.
AVANTI -- A database system developed by ABB. AVANTI contains a database as well as

tools for access and maintenance of the database.
Blocking -- The function is used to inhibit specific types of processing of acquired data.
It is possible to block the acquisition of data, the processing of alarms, the control of
power system devices, the execution of calculations and the printout of reports.
Command -- An operator or system initiated command changes the status or value of a

power system object or a control system device. See Dialogue. Commands may be of
the types:
*One-step command (immediate execute)

*Two-step command (with check-back before execute)
Events -- Changes of state in the power or the control system that requires some action
of the operator.
Indication -- A measured point that assume to values

- 0 and 1 for single indications
- 01 and 10 for double indications (the intermediate states 11 and 00 may also occur).
Interlocking -- Conditional check before executing commands.
Measured value -- A concept covering numeric values representing real or imaginary

measuring points in the process.
On-line server -- The active state of a server in a redundant computer system.
Operator's console -- Comprises the equipment by which the operator controls the
process.
Persistent faults -- The persistent fault marking indicates that, after some event, an
abnormal state persists, either in the process, or in the control system.
Picture -- Dynamic information from the database, combined with static graphic
information and general information that can be presented in a window on a CRT.

Each picture has an identity and belongs to a (sub) system and a picture type.
Tagging -- Marking of objects to display important information.
E.g. used for 'work permits' on power system equipment.

Some tags may be used as condition for interlocking.

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 BANGALORE METRO RAIL CORPORATION LIMITED

BANGALORE METRO RAIL CORPORATION LIMITED

 OPERATION & MAINTENANCE MANUAL Page 01

 OPERATION & MAINTENANCE MANUAL Page 02

Sl.No. Description of Content Page No.

1.3 RSS Configuration 15 - 16

1.4 33 kV Distribution Network 17 - 17

1.5 Auxiliary Substations 18 - 18

1.6 Traction Substations 18 - 18

1.7 Third Rail & Stinger System 19 - 19

1.8 Earthing, Bonding & Stray Current Management 20 - 21

1.9 SCADA, ETS & Power Supply Protection System 21 - 22

2.0 ORGANIZATION OVERVIEW

2.1 Organization Chart 23 - 23

2.2 Duties & Responsibilities 24 - 30

3.1 Safety Information 31 - 33

 OPERATION & MAINTENANCE MANUAL Page 03

Sl.No. Description of Content Page No.

1.2 RSS Scheme 35 -35

1.3 RSS Layout 36 – 36

1.4 RSS Operation Logic 37 - 38

1.5 66 kV Feeders & RSS Protections 39 – 41

1.6 Metering at 66 kV Level 42 - 42

2.0 RSS EQUIPMENTS 43 - 43

2.1 66/33 kV Power Transformer

2.1.1 Technical Specification 44 - 49

2.1.2 Operation of Transformer 50 – 50

2.1.3 Energization Procedure 50 - 51

2.1.5 General Supervision & Maintenance 52 - 54

2.1.6 Maintenance Schedule 55 - 57

 OPERATION & MAINTENANCE MANUAL Page 04

Sl.No. Description of Content Page No.

2.2 66 kV Circuit Breaker

2.2.1 General Description 58 - 58

2.2.2 Technical Specifications 59 – 61

2.2.3 Operating Mechanisms 62 – 63

2.2.4 Closing & Opening Operations 64 – 64

2.2.6 Maintenance Schedule 65 - 66

2.3 66 kV Current Transformer

2.3.1 General Description 67 – 68

2.3.2 Technical Specifications 69 – 70

2.3.3 Operation Parameters 70 - 70

2.3.4 Filling Procedure of CT with Gas – SF 6 71 – 72

2.3.5 General Supervision & Maintenance 73 - 73

2.3.6 Maintenance Schedule 73 - 74

2.4 66 kV Potential Transformer

2.4.1 General Description 75 – 76

2.4.2 Technical Specifications 77 – 78

2.4.3 Filling Procedure of PT with Gas - Nitrogen 79 – 79

 OPERATION & MAINTENANCE MANUAL Page 05

Sl.No. Description of Content Page No.

2.4.4 Oil Filtration 79 – 80

2.4.5 General Supervision & Maintenance 80 – 81

2.4.6 Maintenance Schedule 81 - 82

2.5.1 General Description 83 - 88

2.5.2 Technical Specifications 89 - 90

2.5.3 Isolator Installation Procedure 91 - 91

2.5.4 Earth Switch Installation Procedures 92 - 92

2.5.5 Operating Instruction 93 - 93

2.6 Neutral Grounding Resistor

2.6.1 General Description 96 – 97

2.6.2 Technical Specifications 98 – 99

2.6.3 Operation Mechanism 99 – 100

O & M Manual1-Traction

O & M Manual1-Traction