Final Work Instructions - Electrical Erection

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 1 of 111

Work Instructionsfor Equipment Erection- SF6 Circuit Breaker (1) SCOPE :Document describes the Work Instructions for erection of CB from 66 kV to 765 kV switchyard .

(2) APPLICABILTY:This procedure is primarily developed for Distribution works & applicable to the same, at sites across all locations as per specification.

(3) REFERENCE DOCUMENTS :Following Documents / Drawings / Codes have been referred for the preparation of this procedure:a)IS : ------b)Field Quality Plan (FQP) c) Approved CT GA drawings d) Equipment structure completion & inspection report.

(4) RESPONSIBILITY: Responsibility of implementation of this procedure rest with below mentioned officials a) PRIMARY: Site Engineer / Supervisor b) SECONDARY: Project Manager

(5) PREREQUISITE: A) Complete Foundation B) Structure Erection C) Stringing Completion

(6) TOOLS & TACKLES: a) Lifting Tools& Tackles b) Crane , Man Lifter c) Electrician Toolbox Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 2 of 111

(7) ERECTION PROCEDURE :(7.1) HANDLING a) Lifting the material through crane& slings from store to erection area using guide rope to b) avoid swing during shifting. c) The circuit breakers are to be erected, tested and commissioned as per the instructions given in the Erection, Installation & Commissioning Manual of the Manufacturer. (d) The services of the Manufacturer’s Erection & Commissioning Engineer may be utilized wherever required.

(7.2) PREPARATION (1) Assemble the supporting structure(s) if the members are received in loose condition. (2) Erect the supporting structure(s) on the foundation and carry out their levelling, centering and grouting. (3) Level the top of the already erected supporting structure(s) and check their verticality.

(7.3) Erection Procedure: (1) Clean the insulators of the breaker poles and check for cracks in the insulators. (2) In case of SF6 Circuit Breakers, check that there is positive pressure of the SF 6 gas in the breaker poles, and the support columns if provided, by opening the cover of the pipe connection and pressing the non – return valve (3) In case of CBs received with poles already fitted on a common base channel, erect the base channel along with breaker poles on the supporting structures. (4) In case of CBs with common base channel but in which the poles are received separately, first erect the base channel on the supporting structure(s) and carry out levelling. Thereafter, erect the poles on the base channel. Erect the middle pole first followed by the side poles In case of CBs in which the poles are to be erected on the operating mechanism, first erect the operating mechanisms on the supporting structures and carry out levelling. Thereafter, erect the CB poles on the operating mechanisms.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 3 of 111

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 4 of 111

5) In case of other types of CBs, erect the CB poles on the supporting structures. (6) In case of CBs with horizontal arc chambers, first erect the support columns on the (7) Fit the pre – insertion resistors and voltage grading capacitors, if provided, on the arc chambers. (8) Thereafter erect the arc chamber assemblies on the support columns of individual phases. (9) Check the verticality of the erected poles of the CBs and correct the same wherever required. (10) Erect the operating mechanism / operating drive on the supporting structure of the designated phase, or on all the three individual phases / poles, or on the common structure, or on the common base channel, as applicable. (11) Fit the terminal connectors on the three poles of the breaker

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 5 of 111

Gas Filling in SF6 Gas Circuit Breakers for following criteria: (A) With Gas Density Monitors on Individual Poles (B) Circuit Breakers having Pneumatic Operated Mechanism (C) Circuit Breakers having Spring Operated Mechanism:

Gas Handling UnitGas filling Pipe & Density Monitor & Nozzles

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 6 of 111

(A) With Gas Density Monitors on Individual Poles (1) Fit the SF6 gas density monitor on the support structure / base channel as provided and connect to the SF6 gas pipeline. (2) Connect the SF6 gas pipeline to one pole & fill SF6 gas in the pole up to about 2 kg / cm2. Check for leakage of SF6 gas in the pole and in the SF6 gas pipeline. Attend to the leakages, if any (3) Fill SF6 gas in the pole up to the prescribed rated / filling pressure. The filling pressure should correspond to the ambient temperature at the time of filling as per the chart given in the manufacturer’s manual. The setting and operation of the lockout contacts (closing) and the alarm contact (opening), provided in the density monitor, are checked during SF 6 gas filling. (4) Connect the SF6 gas pipeline to the second pole. The gas pressure in the first pole will fall. Check for leakage of SF6 gas in the second pole. Attend to the leakages, if any. (5) Fill the SF6 gas in the two poles simultaneously up to the prescribed rated / filling pressure. (6) Connect the SF6 gas pipeline to the third pole. (7) Check for leakage of SF6 gas in the third pole. Attend to the leakages, if any. (8) Finally fill SF6 gas in all the three interconnected poles up to prescribed rated / filling pressure. (9) Ensure that the alarm and lockout contacts are in normal condition after SF6 gas filling.

(C) Circuit Breakers having Spring Operated Mechanism: (1) ENSURE THAT THE CLOSING SPRING IS FULLY DISCHARGED. If it is not fully discharged, then discharge the spring as per instructions given in the manufacturer’s manual. (2) Carry out slow mechanical operation (closing and tripping) of Circuit Breaker as per procedure prescribed by the manufacturer. Take all the precautions mentioned in the manufacturer’s manual. (3) Manually charge the closing spring and check electrical limit switch, mechanical latches and stopper(s) as provided. (4) Discharge the spring as per directions in the manufacturer’s manual. (5) Charge the spring electrically and verify the operation of the limit switch. Adjust the setting of the limit switch if required. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 7 of 111

(7.4) FINISHING : Phase marking as per approved drawings Earthing connections of CB to be done

(8) ACCEPTANCE CRITERIA :Conformity to Technical & Standard Specifications. Verticality as per section drawing Erection as per Product Manual

(9) SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Ensure that the material shouldn’t be handled with bare hands, hand gloves shall be used. All precautions to be taken as per manufacturers Installation Manual

(10) RECORDS: Equipment Installation Checklist (as per Client).

(11) MODE OF MEASUREMENT: Quantity in Nos as per customer BOQ

(12) CHECK LIST:As per Attached Annexure-A

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 8 of 111

Checklist for Circuit Breaker Erection ( Annexure-A) 1 2 3 4 5 6 7 8 9 10 11 12 13

Alignment of the structure

Ok/Not Ok

Ensure tightening of hardware used as per approved structure dwg

Ok/Not Ok

Connect to earthing grid at least at two points, Check earthing of the poles, base channel, control cubicle, operating mechanism and structure(s), as applicable

Ok/Not Ok

Check the alignment of interconnecting rod.

Ok/Not Ok

Check the wiring between breaker to breaker marshalling box.

Ok/Not Ok

Check for the phase marking.

Ok/Not Ok

Check the Pressure for SF6 gas Ok/Not Ok Check Air pressure / Oil pressure / Spring charging limit switch contacts for auto reclose blocking. Ok/Not Ok Check alarm annunciations in the C&R Panel for low SF6 gas / air / oil pressure alarms Ok/Not Ok & lockout conditions and for loss of N2 pressure. Check operation of anti – pumping / hunting relay by giving continuous closing and tripping signals simultaneously. The breaker should close and then trip and should not close again. Ok/Not Ok Check for leakage of SF6 gas from all the points (e.g., joints, couplings, cementing on insulator & metallic joints, brazing, etc.) and attend if any leakage is detected

Ok/Not Ok

Lubricate all the moving parts & the Pins in the operating mechanism

Ok/Not Ok

Check Resistance of of closing and tripping circuits.

Ok/Not Ok

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 9 of 111

WorkInstructions for Equipment Erection-- CT (1) SCOPE :Document describes the Work Instructions for erection of CT from 66 kV to 765 kV switchyard .

(2) APPLICABILTY:This procedure is primarily developed for Distribution works & applicable to the same, at sites across all locations as per specification.

(3) REFERENCE DOCUMENTS:Following Documents / Drawings / Codes have been referred for the preparation of this procedure:a)IS : ------b)Field Quality Plan (FQP) c) Approved CT GA drawings d) Equipment structure completion & inspection report.

(4) RESPONSIBILITY:Responsibility of implementation of this procedure rest with below mentioned officials a) PRIMARY:, Site Engineer / Supervisor b) SECONDARY: Project Manager

(5) PREREQUISITE: A) Complete Foundation B) Structure Erection C) Stringing Completion

(6) Tools & Tackles: a) Lifting Tools & Tackles b) Crane c) Electrician Toolbox

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 10 of 111

(7) PROCEDURE FOR EQUIPMENT :7.1 HANDLING a) Lifting the material through crane & slings from store to erection area using guide rope to b) Avoid swing during shifting. c) Tie up equipment with web sling

7.2 PREPARATION a) Check the final structure alignment b) Check the terminals of CT (P1/P2) c) IR Values to be measured before erection d) Tan Delta Point must be Earthed Properly before charging

7.3 ERECTION Erect equipment on structure by crane with balancing guide rope. A) Aluminum ladder to be used for removing the slings from Crane and for fixing the equipment bolt on structure. B) Final tightening of nuts & bolts to be done .

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 11 of 111

(8) ACCEPTANCE CRITERIA:Conformity to Technical & Standard Specifications. Polarity as per SLD Verticality as per section drawing

(9) SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Ensure that the material shouldn’t be handled with bare hands, hand gloves shall be used. All precautions to be taken as per manufacturers Installation Manual

(10) RECORDS: Equipment Installation Checklist (as per Client). Field Quality Plan (as per Client)

(11) MODE OF MEASUREMENT: Quantity in Nos as per customer BOQ

(12) FINISHING : Phase marking as per approved drawings Earthing connections of CT’s to be done

(13) CHECKLIST:As per attached ANNEXURE-A

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 12 of 111

CT Erection Checklist ( Annexure –A) 1 Alignment of the structure

Ok/Not Ok

2 Ensure hardware used as per approved structure dwg

Ok/Not Ok

3 Connect to earthing grid at least at two points

Ok/Not Ok

4 Ensure the correct direction of P1 and P2

Ok/Not Ok

5 Ensure shorting and grounding of unsed core at marshlling box

Ok/Not Ok

6 CT Marshalling box to be earthed

Ok/Not Ok

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 13 of 111

Work Instructions for Equipment Erection-CVT (1) SCOPE :Document describes the Work Instructions for erection of CVT from 66 kV to 765 kV switchyard .

(2) APPLICABILTY :This procedure is primarily developed for Distribution works & applicable to the same, at sites across all locations as per specification.

(3) REFERENCE DOCUMENTS :Following Documents / Drawings / Codes have been referred for the preparation of this procedure:a)IS b)IEC c)Field Quality Plan (FQP) d) Approved CVT GA drawings e) Equipment structure completion & inspection report.

(4) RESPONSIBILITY: Responsibility of implementation of this procedure rest with below mentioned officials a) PRIMARY: Site In-Charge, Site Supervisor, Site Engineer b) SECONDARY: Project Manager

(5) PREREQUISITE: A) Complete Foundation B) Structure Erection C) Stringing Completion

(6) TOOLS & TACKLES: a) Lifting Tools & Tackles b) Crane c) Electrician Toolbox

(7) PROCEDURE FOR EQUIPMENT :Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 14 of 111

7.1 HANDLING a) Lifting the material through crane & slings from store to erection area using guide rope to b) Avoid swing during shifting. 7.2 PREPARATION a) Clean the insulators of the VTs. b) Measure the IR values of primary terminal to earth with 5 kV Megger. c) Check the final structure alignment 7.3 ERECTION a) The CVT or its individual units should be kept shorted and earthed to prevent shock from accumulated charge. This shorting may be temporarily removed for testing. The shorting should be finally removed before energizing the CVT. b) Assemble the different units of the same serial number of the CVT, if applicable c) A ferrule ‘E’ is generally used as prefix of the ferrule markings for indicating the wires of different cores of the VTs.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 15 of 111

The different cores of the secondary winding of the VT are used for the following purposes

7.4FINISHING (1) Carry out laying of cables from secondary terminal box of the VTs to the bay Marshalling Kiosk / Junction Box. (2) Fix the cables in cable glands and then fix the cable glands on cable gland plates in the respective equipment. (3) Connect all the cores of the secondary winding from the secondary terminal box of CVTs (R, Y & B phases) to the Marshalling Kiosk / Junction Box. (4) The cores of CVTs which are not used should be left open. One end of these windings must be earthed in the Marshalling Kiosk / Junction Box. (5) Dress and fix the cables in cable trays / trenches / supports / brackets. The secondary windings of different phases of CVTs are connected either in star or open delta. Typical wiring connections of 2 core CVTs and PTs in the Bay Marshalling Kiosk / Junction Box are shown below

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 16 of 111

(8) ACCEPTANCE CRITERIA:(1) Earth the HF Terminal of CVT, if it is not used for PLCC system. (2) Check that the formation of the star / neutral point or open delta connections of the secondary windings of the three phases of the VTs has been made correctly and that the neutral end of the star connected winding and one end of the open delta connected winding have been earthed in the Marshalling Kiosk / Junction Box. (3) Check the tightness of the connections of the wiring of the secondary windings in the secondary terminal box and in the Marshalling Kiosk / Junction Box. (4) Check the earthing of the CVTs. (5) Check that the fuses provided in the CVT secondary circuits are of correct rating and that there is proper grading of the fuses. (6) Check that there is no shorting in the wiring of the secondary circuit of the CVTs. (7) Check that the temporary shorting and earthing of the CVT or its units has been removed. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 17 of 111

(8) Conformity to Technical & Standard Specifications. (9) Verticality as per section drawing

(9) CHECKLIST:As per attached ANNEXURE-A

(10) SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Ensure that the material shouldn’t be handled with bare hands, hand gloves shall be used. All precautions to be taken as per manufacturers Installation Manual

(11) RECORDS: Equipment Installation Checklist (as per Client).

(12) MODE OF MEASUREMENT: Quantity in Nos as per customer BOQ

(13) FINISHING: Phase marking as per approved drawings Earthing connections of CVT’s to be done

S.no

CVT Erection Checklist

Remarks

1 Alignment of the structure

Ok/NotOk

2 Ensure hardware used as per approved structure dwg

Ok/NotOk Ok/NotOk

3 Connect to earthing grid at least at two points 4 Ensure the correct direction of Terminals Ensure shorting and grounding of unused core at 5 marshalling box 6 CVT Marshalling box to be earthed

Ok/NotOk Ok/NotOk Ok/NotOk

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 18 of 111

Work Instructions for Equipment Erection- Isolator (1) SCOPE :Document describes the Work Instructions for erection of Isolators from 66 kV to 765 kV switchyard .

(2) APPLICABILTY :This procedure is primarily developed for Distribution works & applicable to the same, at sites across all locations as per specification.

(3) REFERENCE DOCUMENTS:Following Documents / Drawings / Codes have been referred for the preparation of this procedure:a) IS : ------b) Field Quality Plan (FQP) c) Approved CT GA drawings d) Equipment structure completion & inspection report.

(4) RESPONSIBILITY: Responsibility of implementation of this procedure rest with below mentioned officials a) PRIMARY: Site In-Charge, Site Supervisor, Site Engineer b) SECONDARY: Project Manager

(5) PREREQUISITE: A) Complete Foundation B) Structure Erection C) Stringing Completion

(6) TOOLS & TACKLES: Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 19 of 111

a) Lifting Tools & Tackles b) Crane c) Electrician Toolbox

(7) ERECTION PROCEDURE Types of Isolators:(1) Double Break Isolators These have three stacks of post insulators. The central post insulator carries a tubular or flat male contact which can be rotated horizontally with rotation of central post insulator. This rod type contact is also called moving contact. The female type contacts are fixed on the top of the other post insulators which fitted at both sides of the central post insulator. The female contacts are generally in the form of spring loaded figure contacts. The rotational movement of male contact causes to come itself into female contacts and isolators becomes closed. The rotation of male contact in opposite direction make to it out from female contacts and isolators becomes open.

(2) Single Break Isolators The contact arm is divided into two parts one carries male contact and other female contact. The contact arm moves due to rotation of the post insulator upon which the contact arms are fitted. Rotation of both post insulators stacks in opposite to each other causes to close the isolator by closing the contact arm. Counter rotation of both post insulators stacks open the contact arm and isolator becomes in off condition. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 20 of 111

(7.1) HANDLING (a) Lifting the material through crane & slings from store to erection area using guide rope to (b) Avoid swing during shifting. (c) Tie up equipment with web sling

(7.2) PREPARATION (1) Level the already erected structure(s) and carry out minor fabrication works, if required, for erection of the Isolator and operating mechanism(s).

(7.3) ERECTION (1) Erect the 3 nos. base frames of individual phases on the structure(s). (2) Carry out levelling and centring of the base frames. (3) Fix the link pipes on the rotating parts of the base frames of the individual phases. (4) Clean and assemble the Support insulator / insulator stack, as applicable. For single break isolators, there will be six Support insulators / insulator stacks whereas for double break Isolators, the quantity will be nine. (5) Fit the male and female contact arms on the Support insulators / insulator stacks in case of single break Isolator. In case of double break Isolator, 6 nos. fixed contacts and 3 nos. moving contacts are fitted on the Support insulators / insulator stacks. (6) Fit the fixed contacts of earth blades in case of Isolator with Earth Switch. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 21 of 111

(7) Fix the arcing horns (make before & open after the main contacts) or corona rings, as applicable. (8) Erect the above assemblies on the rotating parts of the base frames. (9) Carry out adjustment / alignment of individual phases for smooth opening and closing and proper making of contacts. (10) Fit the inter – phase connecting pipes between the rotating parts of the base frames of the individual phases, including fixing of hardware for interlocking with earth switch wherever provided. (11) Fit the operating mechanism box for the Isolator. (12) Fit the main operating down pipe to operating mechanism for the Isolator. (13) Check the operation and final adjustment / alignment of all the three phases of main Isolator for smooth, synchronized and complete operation as one unit. (14) Adjust the mechanical end stoppers on the base channel for both the closed and open positions. (15) Fit the terminal connectors on the Isolator.

(7.3.1) ERECTION OF EARTH SWITCHES: (1) Fix the earth blade mounting arrangements on the base frames of all the three phases. (2) Fit the moving contact (earth blade) of the earth switches and counterweights, wherever provided. (3) Carry out the operation and adjustment / alignment of earth switch of each phase for smooth opening and closing and proper making of contacts. (4) Fit the inter – phase connecting pipes between the earth switches of the individual phases, including fixing of hardware for interlocking with main Isolator. (5) Fit the operating mechanism box for the earth switches. (6) Fit the main operating down pipe to operating mechanism for the earth switch. (7) Check the operation and final adjustment / alignment of all the three phases of the earth switch for smooth, synchronized and complete operation as one unit. (8) Carry out the adjustment and setting of mechanical interlock between main Isolator and Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 22 of 111

earth switch to ensure that earth switch does not operate if the main Isolator is closed, and that main Isolator does not operate if the earth switch is closed. (9) Carry out the adjustment of mechanical end stoppers for the OPEN position of earth switch. (10) Fit the earth bonds and other accessories as provided

(7.3.2) OPERATING MECHANISM: Carry out the adjustment and setting of auxiliary switches. Carry out the adjustment of limit switches in CLOSED and OPEN positions of Isolator in case of motor operated mechanism. Carry out the adjustment of mechanical end stoppers for both the CLOSED and OPEN positions. Carry out the adjustment of interlocking coil and plunger in CLOSED and OPEN positions.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 23 of 111

(8) FINISHING : Phase marking as per approved drawings Earthing connections of Isolators to be done

(9) ACCEPTANCE CRITERIA :Conformity to Technical & Standard Specifications. Verticality as per section drawing Connections as per Section Drawings

(10)SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Ensure that the material shouldn’t be handled with bare hands, hand gloves shall be used. All precautions to be taken as per manufacturers Installation Manual

(11) RECORDS: Equipment Installation Checklist (as per Client).

(12) MODE OF MEASUREMENT: Quantity in Nos as per customer BOQ

(13) CHECKLIST: (1) Lubricate all the moving parts and the pins of the Isolator & earth switch and in the operating mechanism. (2) Check phase sequence of the A.C. supply to the motor and check direction of rotation of isolator, if applicable. Keep the isolator in half closed position before checking the phase sequence. (3) Check operation of Isolator and earth switch for following: i) Smooth operation. ii) Complete insertion and making of contacts in close position. iii) Complete opening of contacts in open position. iv) Functioning of mechanical interlock between main Isolator and earth switch. v) Setting of end stoppers in close and open conditions. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation vi)

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 24 of 111

Operation of auxiliary switches.

(4) Check lamp / semaphore indications, as applicable, in the C&R Panel for Isolator and earth switch OPEN and CLOSED conditions. Also check operation of voltage selection relay, if provided, for Bus Isolators. (5) Check operation of interlocking coil in the Isolator and earth switches. (6) Check operation & verify setting of overload relay / MCBs for motor, as provided. (7) Check operation & verify setting of timer for Isolator operation and pole discrepancy, if provided. (8) Check operation of electrical limit switches in motor operated mechanism. (9) Check local and remote electrical operation of the isolator, including interlocking between main isolator and earth switches, if applicable. (10)Check operation of the electrical emergency opening arrangement, if provided. (11) Check functioning of space heater and internal illumination circuits in the motor operated mechanism.

Checklist For ISOLATOR Check Point

Remarks

Check whether all H/W are used as per approved dwg.

OK / Not Ok

Check the tightness of all hardwares

OK / Not Ok

3

Check the alignment of structure with spirit level

OK / Not Ok

4

Check the alignment of male / female contacts.

OK / Not Ok

5

Check the limit switch for open/close operation.

OK / Not Ok

6

Check the earthing of structure, marshalling box.

OK / Not Ok

Ensure the tightness of connectors

OK / Not Ok

1 2

7

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 25 of 111

Work Instructions for Equipment Erection- Lightning Arrester (1) SCOPE :Document describes the Work Instructions for erection of LA from 66 kV to 765 kV switchyard .

(2) APPLICABILTY:This procedure is primarily developed for Distribution works & applicable to the same, at sites across all locations as per specification.

(3) REFERENCE DOCUMENTS :Following Documents / Drawings / Codes have been referred for the preparation of this procedure:a)IS Codes b)Field Quality Plan (FQP) c) Approved CT GA drawings d) Equipment structure completion & inspection report.

(4) RESPONSIBILITY: Responsibility of implementation of this procedure rest with below mentioned officials a) PRIMARY: Site Engineer / Supervisor b) SECONDARY: Project Manager

(5) PREREQUISITE: A)Complete Foundation B) Structure Erection C) Stringing Completion

(6) TOOLS & TACKLES: a) Lifting Tools & Tackles b) Crane c) Electrician Toolbox Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 26 of 111

(7) PROCEDURE FOR EQUIPMENT :(7.1) HANDLING :(1) Lifting the material through crane & slings from store to erection area using guide rope to avoid swing during shifting.

(7.2) PREPARARTION:(1)The Structure alignment to be checked (2) Cleaning of Insulators (3) The serial number of all the units of a multi – unit Lightning Arrester (LA) should be the same.

(7.3) ERECTION (1) The units of a multi – unit Lightning Arrester should be assembled in the sequence shown on the rating plate of the LA or in the catalogue of the manufacturer. (2) The insulated base unit should be erected in case of Lightning Arresters provided with surge monitors. (3) The installation of the Lightning Arresters should be such that the direction of the open end of the explosion release vent (at top & bottom) is away from adjacent expensive equipment such as transformers. (4) Clean the insulators of the Lightning Arresters. (5) Assemble the different units of the same serial number of the Lightning Arresters, if applicable. Also, carry out fitting of the corona rings between different units, if provided. (6) Erect the Lightning Arresters on the already erected and levelled supporting structure(s). (7) Fit the Surge Monitor on the structure and connect it to the lowest unit of the Lightning Arrester above the base insulator. (8) Fit the corona / grading ring on the top of the Lightning Arrester, if provided. (9) Fit the terminal connectors on the Lightning Arresters.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 27 of 111

(7.4) FINISHING : Phase marking as per approved drawings Earthing connections of LA’s to be done

(8) ACCEPTANCE CRITERIA :(1) Ensure that there is appropriate clearance (Min. 25 mm) between the structure and the connection from the bottom most unit of the Lightning Arrester to the Surge Monitor as shown in the drawing above. (2) For LAs of 132 kV class & above, check the tightness of the connection between the Lightning Arrester and the Surge Monitor, and between the Surge Monitor and earth. (3) Check the tightness of the earthing connection of the Lightning Arrester for 33 kV & 11 kV LAs. (4) Note down the initial readings of the surge counters in the Surge Monitor Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 28 of 111

(5) Conformity to Technical & Standard Specifications. (6) Verticality as per section drawing

(9) SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Ensure that the material shouldn’t be handled with bare hands, hand gloves shall be used. All precautions to be taken as per manufacturers Installation Manual

(10) RECORDS: Equipment Installation Checklist (as per Client).

(11) MODE OF MEASUREMENT: Quantity in Nos as per customer BOQ (12) CHECKLIST As per Attached Annexure-A

Checklist For LA Check Point 1 2 3 4 5 6 7

Remarks

Check whether all H/W are used as per approved dwg.

Ok / Not Ok

Check the tightness of all hardwares

Ok / Not Ok

Check the alignment of structure with spirit level

Ok / Not Ok

Ensure the earthing connections at two points.

Ok / Not Ok

Ensure the earthing strips are insulated from the structure.

Ok / Not Ok

Ensure the LA counter is insulated from structure.

Ok / Not Ok

Ensure the tightness of connectors.

Ok / Not Ok

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 29 of 111

Work Instructions for Power Transformer SCOPE :Document describes the standard procedure for erection of Power Transformer from 66 kV to 765 kV switchyard .

APPLICABILTY :This procedure is primarily developed for Distribution works & applicable to the same, at sites across all locations as per specification.

REFERENCE DOCUMENTS :Following Documents / Drawings / Codes have been referred for the preparation of this procedure:(1) IS codes – IS 10028-2 (2001) (2) Approved Power Transformer GA drawings (3) Field Quality Plan (FQP)

RESPONSIBILITY: Responsibility of implementation of this procedure rest with below mentioned officials :a) Primary: Site Engineer/Supervisor b) Secondary: Project Manager

PREREQUISITE: a) Trafo. Foundation completion with rails fixing. b) Approach Road c) Compaction of area near by Transformer d) Unloading Platform e) Rail Cum Road must be completed

TOOLS AND TACKLES: a) Lifting Tools & Tackles ( As per Manual of Manufacturer) b) Crane/ Hydra c) Electrician Toolbox

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 30 of 111

PROCEDURE :(1) (2) (3) (4)

Handling & Storage at Site Preparation Erection Finishing

(1) HANDLING OF TRANSFORMER AT SITE A) The transformer should be unloaded by means of a crane or suitable lifting device of sufficient capacity (For weight details, please refer the Rating & Diagram Plate). Always use lifting mechanisms, crane, chain pulleys, etc. of adequate capacity. B) Use of any under-capacity lifting mechanism could result in severe damage to the transformer, lifting equipment, or personnel involved in handling the transformer. C) For lifting, suitable lugs are provided on the cover and on the sides of tank. Lifting lugs on the sides of tank are for lifting the complete unit, whereas the lugs provided on the tank cover must only be used for lifting thecover. d) Joint Inspection of Transformer with Client/vendor/OEM erection team must be planned to ensure no break in parts.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 31 of 111

D) Jacking pads are provided to lift the transformer with jacks. Jacks should NEVER be placed under any valves or radiators. Do not use low capacity lifting jacks. Skid type under base channels are provided on the bottom of the transformer, having towing holes for pulling, and mounting holes for the foundation of the transformer. For heavy transformers, the under base is equipped with rollers,slippers allowing the unit to be maneuverer into final position and then anchored. 1.1 Field Storage Instructions:Following procedures should be performed on a monthly basis while the unit is in storage: (1) Inspect unit for any damage (2) Inspect space heaters for proper operation (3) Dry Air or Dry Nitrogen Storage— (A) The transformer must be kept under positive pressure between 3 to 5 psi at all times while in storage. (B) A reserve air supply >10 bar (150 psi) is required to be coupled with a pressure vacuum regulator. (c) If the pressures remain stable, then the interval between readings may be slightly extended. (4) Oil in barrels (A) Insulating liquid supplied in drums or other containers should be placed in a dry location with moderate temperature variation. (B) Drums stored outside must be protected from the possibility of water contamination. (C) If storage exceeds 90 days, it may be necessary to hot oil process the oil prior to placing the oil into the transformer. Oil analyses are the only way to insure the quality of the oil. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 32 of 111

Figure 1-- Storage of Oil Drums

(2) Preparation:It is important that inspection be made upon arrival of the transformer for any signs of damage incurred during shipment. This inspection should be made before removal of the transformer from the truck. The following items should be inspected closely for damage: (1) High voltage and low voltage bushings should be checked for cracks, chips, and leaks. (2) All external accessories should be checked for breakage, loss, and leaks. (3) Tank and radiators should be inspected for leaks, dents, scratches, and other signs of rough handling. (4) Paint should be inspected for damage. (5) Pressure vacuum gauge, liquid level gauge, and top liquid temperature gauge readings should be noted, along with the ambient temperature measurement. (6) Review Impact Recorder tapes to insure that damage has not occurred during transit. Contact the factory .

(3) ERECTION PROCEDURE :(1) Before arrival of the main body, followings should be done; (2) Check the level of the foundation. The horizontal level of the foundation should be as per vendor specification (3) Clean the floor of the foundation and draw base lines on the foundation in accordance with the “FOUNDATION DRAWING” (4).Align up three marks on the main body to the base lines from the front side as shown in Fig.

Pit for Anchor Bolt

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 33 of 111

Base line of foundation

Fig- Aligning marks to be adjusted. 3.1. Assembly Transformers with equipment or accessories removed for shipment must be reassembled after being placed on the installation site. All items removed for shipment will be noted on the Bill of Lading. These items should be reassembled in the following order: De-mounted Radiators Bushings Pressure Relief Device Pressure Vacuum Gauge Fans Rapid Pressure Rise Relay 3.1.1 DE-MOUNTED RADIATORS

(1) After unpacking the radiator package carefully, lift the radiator out from the package and place it in a convenient place for mounting. Hanger

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 34 of 111

Hanger

(2) Remove the blanking iron plates, gaskets from the mounting flanges of the radiator. (3) Set lifting wire rope to the upper hanger. And lift upright the radiator after putting timber underneath the lower hanger as shown in Fig- G1. (4) Lift the radiator up carefully about one-meter from ground and incline the radiator to drain the residual insulating oil in (5) After removing the blanking iron plates and gaskets from the upper and lower radiator valves, confirm that the gaskets are not injured during transportation. And set the gaskets to the gasket grooves of the radiator valves after applying the varnish. (The gasket is replaced to new one which is supplied separately.) CAUTION: Do not remove radiator drain plugs unless replacing them with valves.

Mounting cooling fan 3-1. Mount the cooling fans underneath the radiators as shown in Fig- G2.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 35 of 111

3.1.2 MOUNTING CONSERVATOR FOR MAIN BODY AND O.L.T.C (IF PROVIDED) (1) Mounting conservator for main body. (2) Mount the conservator supports and their reinforcements on the position. (3) Lift the conservator up with mobile crane and mount it on its supports. (4) Connect the Buchholz relay and the pipes between the conservator and the main body using the gaskets and bolts. (See Fig- H1.) (5) Adjust the conservator position with moving the conservator and tightening the bolts between the bushing turret and conservator supports, and between the conservator supports and conservator. (6) After confirming the conservator position is adjusted correctly, connect the conservators and the bushing turret.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 36 of 111

2. Mounting conservator for OLTC. Mounting oil level gauge.(See Fig- H2) Confirm that the contact operations, ON/OFF of the oil level gauge are correct. (1) Confirm that the insulation resistance is more than 100MΩ by 500V megger. (2) Mount the assembled oil level gauge on the conservator with gasket and bolts on the floor.

Mounting conservator for OLTC. (1) Mount the conservator on the main tank temporarily. And mount the oil pipes from the OLTC protective relay using the bolts and gaskets. (2) Connect the conservator and OLTC protective relay using the oil pipe，bolts and gasket. (3) Fasten the bolts between the main body and conservator.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 37 of 111

3.1.3Bushing Installation 

Unpack the package of bushings by the assembly floor. And confirm that the bushings are not broken. 

Before attaching, clean the porcelain surface and the terminal portion on oil immersed side should be cleaned carefully with a clean and dry cloth or with solvent.

The bushing should undergo power factor and capacitance testing, HV Testing prior to its installation onto the transformer. CAUTION: When lifting bushings, always take care to keep the upper end above the lower end, to avoid the possibility of introducing any gas bubble(s) into the bushing insulation. Clean bushings with dielectric solvent prior to installation

How to Lift upto 300kV Class Bushing a) Cranes are used to lift up the bushing as shown in fig-2 b) Lift up the bushing horizontally about 2m in height by crane1 & crane2 as shown in fig.2 & then raise the bushing gradually with crane1. After putting upright the bushing, remove the rope from crane2.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 38 of 111

3.1.4 INTERNAL LEAD CONNECTION (1) During internal job the insulation materials are exposed to open air. Therefore it is essential to do this work onNON-rainy day. (2) Oil level is lowered till bottom of the main body. (3) Clean around the hand hole before opening the hand hole, and before starting the internal job. (4) Never allow anyone to do the internal job before measuring the oxygen density of the main tank. The internal job should be carried out after confirming that the oxygen density is shown more than 18%. (5) Name and quantity of tools used internal job should be recorded before starting the job and checked after finishing the job.

Tool Name Spanner Hammer Flashlight Knife Sheet

Quantity 4 2 1 1 10

(6) The tools used internal job should be attached to line made of clean cotton tape or string so that they cannot be lost. (See Fig- to be inserted) (7) Clothes must be clean. Before starting the job, brush work clothes off and empty all pockets. And the worker should take wrist watch off and confirm that screws of glasses are not loosened. (8) The top of the coil group should be covered completely with clean cotton/vinyl sheet as shown in Fig-, so that foreign material do not enter the coil group. (9) Connect all of the internal leads and the bushings according to the instructions of the Electric supervisor. Connect the internal lead and the lower terminal of the bushing with the bolts and nuts. (10)After finishing all of the internal lead connections, confirm that all of the fastening points are tightened correctly. (11) Wrap the internal lead and the connection point according to the instruction of the Electric supervisor. (12)Bring all of the tools out and take all of the sheets out from the main body. And inspect following items:(a) Insulation distances between the internal lead and the other internal lead, the internal lead and the main body and the internal lead and core are maintained. (b) Damaged point and dirty point is nothing. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 39 of 111

(13)Close the hand hole and fill the main body with oil up to the level that the coil group is immersed

3.1.5Pressure relief Valve

This device can be installed prior to vacuum oil filling, as it withstands vacuum

3.1.6 Pressure Vacuum Gauge Remove the 1/4" pipe plug located on the tank front and approximately 5" below the top cover. Install the gauge, and tighten using Teflon sealing tape.

3.1.7Rapid Pressure Rise Relay Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 40 of 111

Install the rapid pressure rise relay at the top of the tank. This relay should be positioned with the lead connector down if mounted in the horizontal position for proper operation. Connect the flexible lead connector between the control box and the rapid pressure rise relay connector

3.1.8 Initial oil filling in Transformers: Oil Preparation: The oil supplied in oil drums (for first filling, topping up & OLTC) is first filled into oil storage tank(s) through filter machine. This oil is then filtered in the tank(s). The following oil values shall be attained so as to facilitate early and effective dehydration of transformer: a) b)

Break Down Voltage: Moisture Content:

70 kV (Minimum) 10 ppm (Maximum)

The oil temperature thermostat in the filter machine should be set at 60°C. The treated oil shall then be filled into the transformer tank under vacuum until the oil level reaches 250 mm below the top cover level. The oil level can be seen in the transparent plastic pipe provided. The vacuum in the tank is then slowly released by slightly opening the valve on which the breather is connected so that only moisture free air goes inside the tank. The rate of release of vacuum should be kept very slow so that the silica gel in the breather does not get sucked into the tank Dehydration of Transformer by Hot Oil Circulation: When starting the dehydration, oil is drawn from the bottom of transformer into the filtration plant and let into transformer again at the top for removing any settled moisture / impurities. The readings of IR values shall not be taken during this process since these will be misleading due to erroneous indication of winding temperature. After about 8 – 12 hours of circulation in this manner, the cycle is reversed, i.e., oil is drawn from the top and fed at the bottom. During dehydration, measure insulation resistance values of the transformer every 2 hours. The test voltage of 5 kV is applied for one minute. The winding temperature is assumed to be the same as top oil temperature under steady state conditions. Allow the transformer to cool down to atmospheric temperature. Measure the IR values at 2 hour intervals during the cooling period. IR values can be plotted against time. A typical indicative drying out curve is shown below The following oil values shall be attained in order to increase the time interval before re - filtration of oil is required when the transformer is in service: Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation a) b)

Break Down Voltage: Moisture Content:

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 41 of 111

80 kV (Minimum) 10 ppm (Maximum)

Compare the insulation resistance values with the following reference values: i) ii)

New transformers: Old transformers:

Factory Test Results. Previous Test Results.

Insulation resistance varies inversely with the temperature. For a 10°C change of temperature, the insulation resistance changes by a ratio generally in the range of 2:1 to 1.4:1. If the specified IR values are achieved, the transformer can be charged.

(1) Make recirculation degassing of transformer oil in oil fitter, and open valveafter confirming there is no bubbles in the transformer oil, then fill the oil into transformer. (Before filling oil, pull vacuum in oil filter and oil filling pipe first.) (2) When the transformer oil level reaches standard value, close valve. (3) When transformer oil level gauge reaches value “2.0~2.5”, close valveand valve, and then Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 42 of 111

stop the vacuum oil pump. (4) Fill oil and stop oil filling when the oil level gauge of conservator indicates value “3”, and close valve. Then open valveslowly to release the vacuum in rubber bag. (5) After reaching the atmospheric pressure, filling the degassing oil into transformer to achieve adequate oil level in accordance with the temperature of transformer oil level curve and oil temperature. Close valveafter oil filling is completed. (6) In the meanwhile, filling the oil into OLTC to achieve adequate oil level in accordance with the temperature of oil level curve of OLTC and oil temperature. At this time remove the transparent glass vacuum U pipe between valve and, and open valve. Then open valveand valve slowly to adjust the oil level of OLTC. (7) Close valveand remove the transparent glass vacuum U pipe that connect valveand valve, and then tighten up valveand valvewith covers. Finally, assemble the OLTC breather on valve.

ACCEPTANCE CRITERIA :-

Item

The contents of management

Criteria

1

On base of main body

1)

Levelling of foundation

As per Specification/ Manufacturer Guideline

2)

Adjusting centre lines of 3 point

As per Specification/ Manufacturer Guideline

2

Insulated oil relation

1)

Breakdown voltage(At the acceptance of insulation oil)

As per Specification/ Manufacturer Guideline

2)

Breakdown voltage(At the oil filling to the main body)

As per Specification/ Manufacturer Guideline

3)

Breakdown voltage(After the final oil filling)

As per Specification/ Manufacturer Guideline

4)

Moisture content(Final)

As per Specification/ Manufacturer Guideline

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 43 of 111

3

Insulation resistance relation

1)

Insulation resistance of bushing

As per Specification/ Manufacturer Guideline

2)

Insulation resistance of protective relay & device

As per Specification/ Manufacturer Guideline

3)

Insulation resistance of protective circuit

As per Specification/ Manufacturer Guideline

4

Oil leakage test relation

1)

Pressurization value

As per Specification/ Manufacturer Guideline

2)

Pressurization time

As per Specification/ Manufacturer Guideline

5

Vacuum relation

1)

Vacuum degree

Less than 665Pa(5.0 Torr)

2)

Vacuum hold time

More than 4 Hours

3)

Sitting time for the energize

More than 36 Hours

6

The shock under transportation

1)

Impact recorder

Less than 29.4m/S2(3G)

SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Ensure that the material shouldn’t be handled with bare hands, hand gloves shall be used. All precautions to be taken as per manufacturers Installation Manual

RECORDS: Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 44 of 111

Equipment Installation Checklist (Annexure -A). Impact Recorder Graph

MODE OF MEASUREMENT: Quantity in Nos as per customer BOQ

FINISHING : (1) This item applies to the external surface painting of the main tank or the parts which are damaged or welded during transportation and erection (2) Wash away the oil, grease, dirt and dust using the organic solvent for removing fat and wipe out by the wasterags, then dry it up. (3) Polish the surface to be painted using emery cloth #200 - #320, and then clean the surface again. (4) After cleaning, mix and stir the wash primer base and additives, add the thinner of 10-20% (d)Paint the materials by the brush uniformly. (e)Drying time ; Summer season (20℃ or more) Winter season (Less than 20℃)

Natural drying more than 2-3 : hours. Natural drying more than 4-5 : hours.

(5) Welding portion (a)Remove the paint film burned by the welding using the wire brush and steel chisel. (b)Remove the scale and rust on the welded portion using the wire brush and steel chisel. (c)Wash away the oil, grease, dirt and dust using the organic solvent for removing fat and wipe out by the wasterags, then dry it up.

Sr. No.

Activity

Check list

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 45 of 111 Ok/Not Ok

1

1. Mark X and Y axis on transformer foundation. 2. Ensure correctness of X and Y axes marking on the transformer w.r.t. the X and Y axes marked on the foundation. 3. Then fix the rollers against any movement.

2

During commissioning: 1. Ensure flow of dry air whenever the tank is exposed to air. 2. Avoid multiple exposure of tank to air. 3. Confirm tightness of bushing leads. 4. Ensure proper alignment and tightness of all nuts and bolts.

Ok/Not Ok

Ok/Not Ok

3

To ensure the following after installation of transformers: 1. All CT cores are properly terminated in CT JB and short and ground unused CT cores. 2. All equipments are connected to the marshalling box. 3. Ensure direction of rotation of fans and pumps as indicated on the equipment. 4. Check auto, manual and standby mode of operation of fans and pumps. 5. Check contacts of Bucholz relay, OSR relay, OTI, WTI, oil pressure of MV bushing, PRV, MOG. 6. Ensure operation of OLTC from remote and local. 7. Ensure MV tap is at nominal tap position.

Ok/Not Ok

4

1. Control cable laying from MB to relay panel as per ICS. 2. Check IR value and continuity of control cable. 3. Ferruling and crimping should be proper. 4. Cable tags should be put as soon as cable is terminated on both end. 5. Close unused cable entries.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

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5

1.Check condition of valves / drain plugs as per OEM instruction. 2. Start vacuuming process as per OEM instruction. 3. Hold vacuum as per OEM inst. 4. If vacuum is OK, start oil filling and filteration. 5. Check cleanliness of filter and ringe the filter and oil drum / tank with new oil which is to be used in transformer. 6. Check BDV and PPM before oil filling in the transformer tank. After oil filling check BDV and PPM.

Ok/Not Ok

6

1. Docking of GIS bus duct on transformer bushing. 2.Termination of LV/MV cbales on transformer. 3. Oil filling in MV box. 4. Commissioning of COPS as per OEM instrcution. 5. After commissioning of COPS install the breather and check oil level is maintained in the breather cup.

7

1. Ensure earthing of transformer as per dwg. 2. Ensure neutral earthing to separate pits. 3. Ensure continuity of earthing with bell tank and bottom tank. 4. Ensure earthing of each equipment at two points. 5. Ensure earthing of fans and motor.

Ok/Not Ok

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

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Work Instructions for Equipment Erection- Wave Trap SCOPE :Document describes the Work Instructions for erection of Wave Trap from 66 kV to 765 kV switchyard .

APPLICABILTY :This procedure is primarily developed for Distribution works & applicable to the same, at sites across all locations as per specification.

REFERENCE DOCUMENTS :Following Documents / Drawings / Codes have been referred for the preparation of this procedure:a) Field Quality Plan (FQP) b) Approved WT GA drawings c) Equipment structure completion & inspection report.

RESPONSIBILITY: Responsibility of implementation of this procedure rest with below mentioned officials a) PRIMARY: Site In-Charge, Site Supervisor, Site Engineer b) SECONDARY: Project Manager

PREREQUISITE: A) Complete Foundation B) Structure Erection C) Stringing Completion

TOOLS & TACKLES: a) Lifting Tools & Tackles b) Crane c) Electrician Toolbox

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

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PROCEDURE FOR EQUIPMENT :(1) HANDLING a) Lifting the material through crane & slings from store to erection area using guide rope to b) Avoid swing during shifting. c) IR Values to be measured before erection

(2) ERECTION A) Level the top plate of the already erected structure for wave trap. B) Assemble the parts of the support Insulators, if applicable. C) Erect the support insulator(s) on the supporting structure. D) In case three support Insulators are provided for each Wave Trap and these are in parts, then the connecting plate between the joints of the parts of the support Insulators is also fitted. E) Hoist the Wave Trap through lifting arrangement F) Erect the Wave Trap on the support insulators G) The Wave Traps are erected as below:S.No .

Line Type

Type of Coupling

Single 1 Circuit

Phase to Phase

2 Double Circuit

Inter – circuit

Phases on which Wave trap has to be erected Two phases of the line Same phase of both the circuits

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

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ACCEPTANCE CRITERIA :Conformity to Technical & Standard Specifications. Verticality as per section drawing

SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Ensure that the material shouldn’t be handled with bare hands, hand gloves shall be used. All precautions to be taken as per manufacturers Installation Manual

RECORDS: Equipment Installation Checklist (as per Client). Field Quality Plan (as per Client)

MODE OF MEASUREMENT: Quantity in Nos as per customer BOQ Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

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FINISHING : Phase marking as per approved drawings Earthing connections of WT to be done

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

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Work Instructions for Gas Insulates Switchgear (GIS) Erection SCOPE:- Document describes the Work Instructions for erection of Gas Insulated Switchgear (GIS) ranging from 66 kV to 765 kV ratings. APPLICABILTY:- This procedure is primarily developed for GIS Substation works & applicable to the same, at sites across all locations as per specification. REFERENCE DOCUMENTS :- Following Documents / Drawings / Codes have been referred for the preparation of this procedure:a) IS Codes b) IEC Codes

RESPONSIBILITY: Responsibility of implementation of this procedure rests with below mentioned officials a) PRIMARY: Site Engineer / Supervisor b) SECONDARY: Project Manager

PREREQUISITE: a) Field Quality Plan (FQP) c) Approved GIS Equipment GA drawings d) Layout arrangement for GIS hall e) OEM Instruction and procedures sequenced for storage, assembly, and testing. f) Neat & clean and air tight / positive pressurised environment of GIS hall g) Layout of GIS storage arrangement showing each packet number. h) GIS foundation completion. i) Lifting Equipments, e.g. Hydra Cranes, EOT cranes Lifting belts etc.

EQUIPMENT AND ACCESSORIES: a) b) c) d) e) f)

Hydra Crane of appropriate capacity Lifting Belts Trolley with rollers Spanners and tool box Vacuum pump Gas handling machine.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

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PROCEDURE FOR EQUIPMENT ERECTION:Material Handling: a) Prepare the sequence of GIS parts to be erected or taken inside the GIS hall, with the help of OEM supervisor. b) Find out and lift the particular packet of GIS equipment as advised by OEM supervisor. c) Use guy rope for tying the packet to avoid any jerk or swing while hydra crane marches from storage area to GIS hall. d) Keep the GIS equipment packet at the door of GIS hall on the trolley. Preparation: 1. Before installing the switchgear panels, make sure that the switch- gear room is checked according to the switchgear documentation. 2. The switchgear is positioned on its site of installation; check the fastening points for flatness. Any unevenness must not exceed OEM recommendations. 3. Remove transport packaging (protective films) of various parts as per the sequence of assembly. 4. Impact Recorder associated with GIS to be checked for any damage during transportation & if any damage is found same to be informed to GIS manufacturer. ERECTION 1. Lift the first bay and position it exactly as per the co-ordinates mentioned in approved drawing. If the bay is transported in separate parts, then first place the breaker unit on insert plate.

2. After placing the first bay/breaker, check the vertical and horizontal levels by spirit level. Any miss-alignment must be taken care by inserting shim plates provided by OEM.

3. Tag welding to be done for temporary fixing of the unit.

4. Further assembly to be done as per the OEM sequence of assembly. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

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5. While assembling two parts, it should be taken care that, the internal parts are exposed to atmosphere for minimum time.

6. Tightening of the nuts and bolts is to be done only by torque wrench with required torque advised by OEM. During installation the tightness of all nuts and bolts are to be checked by torque wrench as prescribed by manufacturer. The bolts are to be tightened alternately (i.e. crisscross) evenly so that there is no deformation in the ‘O’ ring. This will ensure longevity of the ‘O’ ring and avoid future leakages.

7. When the internal parts are exposed to atmosphere, it has to be covered with temporary polythene sheet caps. Before closing the compartment all exposed parts are to be cleaned with alcohol.

8. This process to be followed till the assembly of all the bays / units is over.

9. Simultaneously, the erection of LCC panel, earthing work and control cabling from GIS bay to LCC to be done for reducing the erection time.

10. All tag welding are to be made permanent welding once all the bays are assembled.

11. Once the erection of completed, the vacuum and gas filling process to be started.

12. Open the cover where, desiccant is to be put. After placing the desiccant bag, immediately close the cover and start vacuuming the particular compartment. Ensure that, gas monitoring device is installed before starting vacuum. Once the vacuum is achieved for required duration, start gas filling to required level.

13. This process is to be repeated till all compartments are filled with gas. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

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ACCEPTANCE CRITERIA :Conformity to Technical & Standard Specifications. Conformity to the GIS GA Layout. Conformity to the SLD. Required Gas Pressure SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Since, GIS hall has to be completely dust proof, every person entering the GIS hall must use shoe cover, hair cap, hand gloves and nose masks. All precautions to be taken as per manufacturers Installation Manual.

RECORDS: GIS Equipment Installation Checklist (as per OEM). Field Quality Plan (as per Client) PHOTOS :1. Covering the GIS compartments to arrest ingress of impurity.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

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2. Covering the erection area with net to avoid dust.

3. Tightening of bolts in 1-3-4-5-6-7-8 to avoid damage to ‘O’ ring:

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

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Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

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Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

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MODE OF MEASUREMENT: Quantity in Bays / Diameter as per customer BOQ FINISHING: Phase marking as per approved drawings Earthing connections of GIS equipment to be done

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

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Standard Operating Procedure for Pre-Engineered Building (PEB) Erection SCOPE:- Document describes the Work Instructions for erection of Pre-Engineered Building (PEB) for GIS substations. APPLICABILTY:- This procedure is primarily developed for Substation works & applicable to the same, at sites across all locations as per specification. REFERENCEDOCUMENTS :-Following Documents / Drawings / Codes have been referred for the preparation of this procedure:c) IS Codes

RESPONSIBILITY: Responsibility of implementation of this procedure rests with below mentioned officials a) PRIMARY: Site Engineer / Supervisor b) SECONDARY: Project Manager

PREREQUISITE: a) Field Quality Plan (FQP) b) Manufacturer’s guideline for erection. c) Manufacturer’s Supervision d) Completion of Anchor bolt casting

EQUIPMENTAND ACCESSORIES: g) Cranes, Wire rope, slings

PROCEDURE FOR ERECTION OF PRE-ENGINEERED BUILDING (PEB):Erection process of structural steel involves the assembly of steel components into a frame on the site which also forms the major part of project cost. This process briefly involves lifting and placing components into position, then connecting them as a whole member and finally bolting. So, to ensure that the processes should be completed safely, quickly and economically, it has to be greatly influenced by the decisions made before the erection Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

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commences. Erection cost comprises of 7-10% of the total project cost which is mainly dependent on the speed of execution of erection of the structure. During execution of erection of structure, it is subjected to carry temporary loads which would not be the part of loading in future. The aspects that are to be ensured during execution are safe erection procedures and structural stability of the structure. To focus these aspects, the guidelines for the erection process are presented in this paper. I. INTRODUCTION In steel erection process it involves positioning of the components, aligning it and securing them on prepared foundations to form a complete frame. As a result, a skeletal steel frame can be erected by bolting-up the connections. To enhance the speed of construction and ensure safe process, careful planning is needed. Careful planning involves the maintaining of practical erection sequence and maintaininng simplicity in assembly formation. Site work involves labour intensive tasks and hence cannot be controlled for time purposes. It is also relatively expensive and our primary aim is to minimise the costs by reducing the time on site. For shortening the time on site some of the principal design factors are to be considered such as repetition and standardisation, achievable tolerances, frame type and choice of floor systems. Erection sequence should be formed so as to establish a stable unit as quickly as possible and to attach the subsequent elements directly or indirectly to it. There should also be the proper knowledge of equipment usage and planning for performing safe tasks. II. ESSENTIALEQUIPMENTSFORERECTION The essential equipment for erection activities are as follows: a. MobileEquipment: Mobile equipment mostly comprises of delivery trucks, truck cranes, hoists etc. for PEB construction. To ensure safe processes, certified mobileequipment operators and qualified mobile equipment operators are permitted to enter the site. It is primarily advised not to operate the equipment closer than 4.5 m to a voltage line of 220V or more. On a site, only a signalman is given right to give signals to the operators. Only in case of emergency, others can use this right. b. Slings:Slings are used in lifting operations and hence it should be well inspected for its wear and tear condition. So, to protect slings, they should be padded by sharp corners and the lifted load should not be jerked in any circumstances as jerking might triple the load. This includes chain, wire rope and synthetic slings with its attachments. General tendency is to hang up the sling when not in use. c. Scaffolds:Scaffolds should be placed on a firm ground position and foot bases are well rested on wood planks with minimum size 20cm*20cm. Scaffolds should be planned and installed with some precautions: 1. It should not restrict the crane access and boom clearances making the erection activities complex. 2. Hand rails, midrails, ladders and a platform should be provided at every floor level. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

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Fig. 1: Accessories for lifting components

d. ELCBBox:Electrical system must be standardized including the which should include sealed box, ELCB( 30mA-60mA), 3 pin sealed plugs for outlets. For ease in operation and safety, at least 1 ELCB should be put on the roof installation. e. Hand Tools:Hand Tools should be fixed to the wrist lanyards to prevent it from dropping. Tools which are to carried for certain purposes should have provision for the safe carriage. Proper use of tools should be made and hand tools should be tampered for serving some other purpose of tool. Never use makeshift device.

III. ENGINEERINGDOCUMENTSREQUIREDFORERECTION Before starting of erection work, it is necessary to have clear understanding of engineering documents. Erection drawings and Shipper's list are referred especially for erection work. Erection drawings which are to be referred on site should "ISSUED FOR CONSTRUCTION" which is of latest revision. 'FOR APPROVAL' drawings have some modification in it and so should not be adopted for construction. It is predicted from the revision boxes held at the bottom of the sheet. 1. AnchorBoltSettingPlan It is a plan consisting layout of all bolts for the building. It is normally presented on one sheet but if extent of work is large then it may exceed one page. There are few precautions taken by the engineers that the i. Drawings for erection are proportioned drawings and not up to scale which can be misleading. ii. All the dimensions are given in mm and it includes anchor bolt schedule which is in the orm of table displaying quantities and sizes of anchor bolts. iii. Key plan should be well studied for c/c dimensions, bay spacing, dimensions, bolt setting details and critical dimensions for the span. iv. Also, most important locations where grout is required and identified specifying grout Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

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thickness, grout projection considering the tolerance limit for bolt setting which should not exceed the limits of standards. 2. RoofframingPlan This plan shows the purlins, bracing and other miscellaneous details. It shows part numbers for purlins, bracings, sag rods, strut tubes etc. Hence, these drawings should be studied carefully else critical details might get slipped. For example, nested purlins, strut purlins and strut clips. 3. Cross-Section It is one of the most important drawings as it is referred most frequently. It contains lot of information about columns, rafter refernces, purlins, girts, vertical and roof bracings, conection details, bolt schedules, flange brace schedules and other details as applicable, such as strut tubes, flashing etc. Essential quantity of members can be found out by referring this drawing which is required for cross-checking with shipper's list at pre-planning stage. 4. RoofSheetingLayout It displays roof panels with length and its part number. It also denotes panel lap details, skylight positions, downspout positions, standard details of fasteners, trims and insulation are included. 5. SidewallSheetingandFraming This drawing shows the sidewall framing and sheeting on one or more drawings depending on the extent of work. It shows the part number of girts, eaves struts, bracing and sag rods which helps in finding the position of panels. 6. OtherDrawings It includes mostly accessories drawings such as sliding doors, roll-up doors, personnel doors, windows, louvers and ventilators. Also, mezzanine layots if any are included in it. 7. ShippersList It is generally termed as customer's bill of material. The BOM comprises a coversheet which include job number, building number and phase, customer name, Location, and Building size. The cover sheet also shows the number of phases in the building, any revisions, plus any special notes. The shipper List has 7 columns indicating i. Serial Number ii. Part Number iii. Quantity iv. Revision Number v. Description Of part vi. Colour Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

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vii. Length of item

IV. GUIDELINESFORERECTIONSEQUENCE The structural frames and other parts of the building can be erected in various ways which will depend upon the following key factors: 1. The type of structures such as: small clear span, large clear span, low rise building, high building, open web structure etc. “

Its ensured by checking it roughly that the concerned template fits freely over the bolting arrangement. If it does not fits, then the bolts are made vertical by using the pipe without damaging the threads of the anchor bolt. This ensures proper and correct erection. After that foundation levels are checked and shim packs are placed in the centre of bolt pattern. Top level of all shims should be at the same level and it should be checked by the dumpy level. Step 2: Install Columns at Braced Bay Erection activity always should be proceeded from the start of the braced bay. So the position for the columns should be marked along with their part numbers. From the given figure, refer the columns of braced bays 2-3 and 4-5. To install column A2 follow the procedure as follows: i. Firstly, tighten the anchor nuts and set up the scaffold/ladder at columns. ii. Tie temporary bracings on the two sides of the column which are of PP rope of 20mm dia or wire rope of 12 mm dia minimum. iii. Check the plumb of the column on either sides and slightly release the load on the slings and check the stability of the column and finally remove the slings.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

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Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

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Step 4: Fixing of girts as per the general guidelines stated as below: i. To fix up the all the side girts and tie them between each column provided with the rope with safety-lock hook to lift girts. ii. To tighten the bolts with normal torque and install temporary bracings on two sides of each column. Step 5: Install other side wall columns Install other sidewall columns E1 and E2 and girts by repeating Step 2, Step 3 and Step Step 6: Install the 1st rafter (RF-2) 1st rafter that should be selected should be from the braced bay. Hence, shift all the material towards first braced erection. While shifting, ID mark of the rafter members should be noted and then should be displaced. i. First rafter member is assembled on the ground and then lifted to the lifting position. ii. Torque wrench to tighten hi-strength bolts with recommended torque which is given in the Torque table for high strength bolts. iii. Attach temporary bracing at every 6m and fly bracing to rafters. Attach support pipes D 50*2mm*2m and out-flange of rafters, one at 1m distance from the eave and other right at the top ridge of the rafter end, the pipe on top is used for both roof slopes. Static lines are fixed from pipe to pipe by brackets at 800 mm high from outside flange. iv. Also, the slings are attache to the member at two points about 1/4 from the ends (minimum 3.5m) and next to purlin cleats towards ends. v. It is advised to use more than two points and calculate two major parameters to ensure safe erection. They are as follows: Belt pick-up angle: To avoid distortion of material caused by force Overhang: To prevent distortion of the member caused by weight itself. vi. Install assembled rafter with the help of crane to columns and workers on scaffolds at columns should be made to tighten bolts to a snug tight condition at rafter-column connection plates. Temporary bracing at every 6m to hold the first rafter on 2 sides to anchor bolts groups by V shape cleats or any other immovable object and then the crane is slightly released to check the stability of the rafter before releasing the crane

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

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In this step, the only difference in this step is not releasing the crane until the purlins are

installed and fly bracings are attached at 6 m on both sides of the rafter. These purlins are provided with rope with safety lock hook to pull the purlins above or below. Also, roof and wall bracings are to be erected.

Step 8: Finish 100% of the braced bay The braced bay can be installed fully byPlacing the struts, purlins, fly bracing on the bays and Installing permanent cross bracing for roofs and sides fully at this bay. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

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Fig. 7: Installation of bracing

Step 9: Alignment and Tightening of Braced Bay After completion of the braced bay erection, it should be checked for alignment which is the most critical activity in the erection sequence which avoids future problem in erection. It is recommended as follows: i. Check level of columns and plumb of column on both sides for verticality. ii. Check the rafter alignment by dropping of plumb from rafter at ridge and at every 6m. Alterations can be made by loosening and tightening of cross bracing and also using temporary bracings where required. iii. Fly bracings are also fixed in correct position and finally the coincidence of ridge line and centre-line of the building should be checked. After all these, the situation should be well inspected and tightening the permanent bracing. Step 10: Install the first end frame i. Install all the side and internal columns at line 1 and girts ii. Adjust alignment, position and level with Scaffolds which are set up at each column and tighten anchor bolts. Finally, check the plumb line and tape measure. iii. Tighten all anchor bolts iv. Install the first rafter member to columns Release the crane slightly to check the stability of the rafter before fully releasing of crane. Step 11: Install all remaining columns, rafters and roof purlins i. Install all side and internal columns along with girts in line 4,5 and 6. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

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ii. Adjust alignment, position and level, scaffolds setup at each column and put shims under the base plates which are required. Then the set up should be well inspected and the anchor bolt nuts are tighten after measurement of alignment checks. iii. Repeat the same [step 6] and [step 7] for all rafters and roof purlins

Fig 9: Erection of columns at gable end

Fig 10: Erection of rafters at gable end

Step 12: Install the second end frame i. Install all side and internal columns along with girts at line 4.5 and 6. ii. Adjust the alignment, position and level with the set up of scaffolds at every column. After inspection, anchor bolt nuts are tightened after the alignment checks. iii. Install the first rafter member to the columns by guidelines of above steps. Step 13: Finish 100% Frame & Roof Purlins i. Installion of struts, purlins and fly bracing 100 % for 2 end bays. Cranes are used to pick up struts to roof which possess rope with safety lock hook to pull up purlins, struts manually ii. Installation of permanent cross bracings for columns fully at these bays. Leave the bracing Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 69 of 111

in loose condition. Step 14: Alignment and Tightening Follow [step 9] for alignment and tightening Release some temporary bracings of the building if required

Step 15: Final Inspection: The draft of 'Final Inspection' should be done between the product consultant and Builder. It is done to ensure the quality compliance and planning for repair, clean and touch up. As a part of contract. it is signed off between the technical personnels. The official final inspection shall be completed with a witness of client's representative. The record must be signed off and documented as a part of contract.

ACCEPTANCE CRITERIA :Conformity to Technical & Standard Specifications. SAFETY: Use of safety PPEs like (Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. RECORDS: Field Quality Plan (as per Client)

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 70 of 111

PHOTOS :-

MODE OF MEASUREMENT: Quantity in Bays as per customer BOQ FINISHING : Balance civil work, flooring, painting etc.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 71 of 111

Work Instructions for EOT Crane Erection SCOPE:- Document describes the Work Instructions for erection of EOT Crane for substation ranging from 66 kV to 765 kV ratings. APPLICABILTY:- This procedure is primarily developed for GIS Substation works & applicable to the same, at sites across all locations as per specification. REFERENCE DOCUMENTS:- Following Documents / Drawings / Codes have been referred for the preparation of this procedure:d) IS Codes e) IEC Codes f) Field Quality Plan (FQP) g) GA of building h) GA of EOT Crane i) Manufacturer recommended Erection guideline

RESPONSIBILITY: Responsibility of implementation of this procedure rests with below mentioned officials a) PRIMARY: Site Engineer / Supervisor b) SECONDARY: Project Manager

PREREQUISITE: A) Plane surface of GIS hall B) Lifting Equipments, e.g. Hydra Cranes / winch machine Lifting belts etc. C) Completion Girder. D) Supervision of Manufacturer TOOLS & TACKLES: h) i) j) k)

Hydra Crane/winch machine of appropriate capacity Lifting Belts / Wire Rope Trolley with rollers Spanners and tool box

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 72 of 111

PROCEDURE FOR EOT CRANE ERECTION:Handling of EOT Crane:a)Lifting the material through crane & slings from store to erection area using guide rope to b) avoid swing during shifting. c) Tie up equipment with web sling d) Check the final structure alignment Preparation:(1) The crane should be erected on an un-occupied floor where no industrial or construction work is to be carried out during erection. The size of the floor must ensure free & convenient handling of the crane during the erection period i.e. setting the crane in erecting position on the floor, turning the suspended crane etc. the most convenient place for erecting the crane is the space between the columns provided there are no horizontal bracings connecting the roof trusses. (2) Besides testing the rope & trusses for strength, they should be tested for stability under horizontal forces acting at right angle to the truss plane. (3) The winches employed for lifting the crane should be equipped with ratchet stops. (4) The wire rope employed for erection must have tags indicating wire breaking forces & should be free of defects, fractures, kinks etc. (5) The minimum safer factor should be three for Sling. ERECTION: An E.O.T. crane stands for Electric Overhead Travelling crane. This is used for handling & moving a maximum specified weight of the components called capacity of the crane within a specified area. The crane can be operated manually or by electric power. electrically operated crane can be divided into different sections as follows:(a) (b) (c) (d) (e)

Bridge girders, End carriages, Hoisting trolley also known as crab, Long travel machinery, Driver’s cabin/Floor operation.

Before maintenance of the crane, it is important that some guidance is available to erect the crane to avoid accident & smooth running of the crane. When hoisting the crane or its parts the following conditions should be kept in mind. (a)

The angle of inclination of the slings should not be less than 45º.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 73 of 111

(b) To prevent rupture of the rope due to sharp edges of lifted materials, wooden or metal lining should be used. (c) The number of clamps to be used for fastening the rope should be sufficient. We should also ensure that the axes of the winch drum should be exactly at right angle to rope direction.

Fig.:- Schematic View of E.O.T. Cranes. LIFTING THE CRANE:Depending on the weight of the crane, the strength of the rope, trusses, the crane can be lifted by one winch or two or four winches. If the weight of the crane is not very high the crane structure can be assembled at the floor & the complete crane canbe lifted. in case the crane is very heavy we may lift different portions of the crane in sequence as follows:1. 2. 3. 4.

End carriages complete with L.T. wheels fitted in position. Main girders. Hoisting trolley or crab. Driver’s cabin & other electrical components.

To simplify the positioning of the different components the crane should be match marked at every joint. Every joint should be bolted only by means of machine bolts. 5. It is strictly forbidden to stand or walk under the crane when the crane is being lifted. 6. The scaffolds must comply with the safety rules. The fitter working on top, must handle the parts & tools carefully so as to prevent them to fall down. The erection supervisor must ensure that all the components are assembled in accordance to the sub assembly drawings. After the crane has been fully erected, we must do the electrical Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 74 of 111

connection exactly as per its wiring diagram. Before we actually do the load test we must run all the motions in idle condition. during idle running of different motions we should particularly observe the following:(a) (b) (c) (d) (e)

Eccentric running of moving parts. Alignment of shafts. Fauling of moving components. Any un-usual noise. Presence of lubricant at desired surfaces.

After the idle running of different motions & satisfactory performance of motors, limit switches, brakes & controllers we may go ahead with load testing of the crane in accordance to relevant Indian standards.

Fig.:- Aerial View of E.O.T. Cranes.

ACCEPTANCE CRITERIA :Conformity to Technical & Standard Specifications. Checklist to be referred ( Annexure-A) SAFETY: For the safety of the people engaged in erection work, the following safety rules should be observed:-

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 75 of 111

1. When lifting the crane structure the dangerous zone of assembly must be protected with flags barriers etc. & no un-authorised person should be admitted in the area. 2. Do not lift the crane if the erection area is badly illuminated. 3. Although the lifted structures should not be allowed to suspend for a long time but in case of exception we must see that:(a) The safety factors of the ropes & cross girders should be twice than the normal working. (b) The last line of rope running off the blocked should be clamped near the block. (c) In case the load is lifted by means of hand winch, remove the handles, apply & secure the brakes. (d) Post workers to ensure security. (e) Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. (f) Since, GIS hall has to be completely dust proof, every person entering the GIS hall must use shoe cover, hair cap, hand gloves and nose masks. (g) All precautions to be taken as per manufacturers Installation Manual

RECORDS: EOT Crane Installation Checklist (as per OEM). MODE OF MEASUREMENT: Quantity in Nos. as per customer BOQ FINISHING : Earthing connections of Crane to be done

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 76 of 111

Check List

Sr. No.

Activity

Check

1

Check distances between brackets where EOT rail will be fixed for accuracy. Compare with Engg approved dwg.

Ok/Not ok Ok/Not ok

2

Install the rails on brackets using chain pully.

4

Install girder, hoist and other accessories as per OEM procedure.

Ok/Not ok

Ok/Not ok 5

Conduct operation checks from pendant and RRC. Ok/Not ok

6

Check that all limit switches operate at desired position

7

Conduct load test through competant authority.

8

Measure deflections during load test and compare with GTP.

9

Check that long travel, cross travel, lift height as per specification.

Ok/Not ok

Ok/Not ok

Ok/Not ok

Ok/Not ok 10 Check shrouded bus bar are properly insulated. Ok/Not ok 11

Remove any debris / unwanted material kept on rail track Ok/Not ok Take the EOT in load service.

12

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 77 of 111

Work Instructions for Erection Of Battery Set and Charger. SCOPE :-Document describes the Work Instructions for erection of battery sets. APPLICABILTY:-This procedure is primarily developed for Substation works & applicable to the same, at sites across all locations as per specification. REFERENCEDOCUMENTS:- Following Documents / Drawings / Codes have been referred for the preparation of this procedure:a) Approved Drawings b) IS Codes c) O&M Manual of suppliers d) Approved FQP

RESPONSIBILITY: Responsibility of implementation of this procedure rest with below mentioned officials a) PRIMARY: Site Supervisor, Site Engineer b) SECONDARY:Project Manager,Safety Engineer, Quality Engineer

PREREQUISITE: a) Completion of associated civil works for erection of equipments. b) Completion of ventilation system. c) Acid proof painting on the wall and acid proof tiles on the floor.

EQUIPMENTANDACCESSORIES: a) Lifting Tools& Tackles b) Hand gloves, apron, mask. c) Hygrometer, thermometer, multimeter. d) Electrician Toolbox

PROCEDURE FOR EQUIPMENT ERECTION :ERECTION:Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r)

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 78 of 111

Install the charger set as per location marked in the GA drawing of sub station. Connect AC power source from ACDB to charger as per SLD of ACDB. Connect the cable from charger output to DCDB as per SLD. Connect the cable of required size from battery to the charger.

Before installing the battery set, check the dimensions of the battery room. Arrange the stands as per the approved dwg. Place the batteries as per approved dwg. (Single tier / double tier). The clearance from adjacent wall to battery set to be as per approved dwg. Connect the jumpers and put petroleum jelly at each connection bolts. Pour the acid into the battery carefully and check specific gravity. Start the charging cycle with boost mode as per OEM instruction. After charging for requisite time, start the discharge cycle with connecting the battery output to DC load. Repeat the charging and discharging cycles as per OEM instruction. When charging and discharging cycle is in process, record the specific gravity, temperature and voltage of each cell on hourly basis and compare with OEM requirement. When the charging discharging cycle is completed, keep the battery set in float mode. Check the readings for input current and output current. Also check the input and output voltage. Check for the earth leakage current. Put the serial numbers on each cell.

ACCEPTANCE CRITERIA:Conformity to Technical & Standard Specifications. The output voltage of each cell and the total output voltage should be as per specification. The leakage current should be near to zero. SAFETY: Use of safety PPEs like (Safety Belt, Safety Mask, Helmet, Safety Shoe, Hand gloves, goggles, LOTO) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Ensure that the material shouldn’t be handled with bare hands, hand gloves shall be used. All precautions to be taken as per manufacturers Installation Manual

RECORDS: Equipment Installation Checklist (as per Client). Field Quality Plan (as per Client) Readings taken in charging and discharging cycle.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 79 of 111

PHOTOS :-

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 80 of 111

MODE OF MEASUREMENT: Quantity in Nos as per customer BOQ FINISHING : The numbering of each cell should be done properly. The acid level should be clearly visible.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 81 of 111

Work Instructions for Earthing SCOPE:- Document describes the Work Instructions for Earthing within the substation ranging from 66 kV to 765 kV ratings. APPLICABILTY:- This procedure is primarily developed for Substation works & applicable to the same, at sites across all locations as per specification. REFERENCEDOCUMENTS:- Following Documents / Drawings / Codes have been referred for the preparation of this procedure:j) IS Codes k) IEC Codes

RESPONSIBILITY: Responsibility of implementation of this procedure rests with below mentioned officials a) PRIMARY: Site Engineer / Supervisor b) SECONDARY: Project Manager

PREREQUISITE: a) Field Quality Plan (FQP) c) Approved Earthing Layout and Earthing Details d) Overall substation Layout e) Major Tower and Equipment foundation completion. f) Lifting Equipments, e.g. Hydra Cranes, Lifting belts etc. g) Levelling of substation.

EQUIPMENTANDACCESSORIES: l) m) n) o) p) q)

Hydra Crane of appropriate capacity Lifting Belts Welding Machine Spanners and tool box Gas cutting set Excavator

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 82 of 111

PROCEDUREFOREARTHING:MainGrid: a) Shift the earthing materials e.g. MS Rod etc with the help of Hydra crane or manually as required. Use guy rope for tying the lifted item to avoid any jerk or swing while hydra crane marches from storage area to work area. b) Find out and mark the FGL. c) Mark the Main grid to be laid with the help of lime powder. d) Excavate the main grid with the help of JCB or manually as required. Depth from FGL to be kept as per drawing / specification. e) Make the welding joints on the ground itself before laying. Proper overlap as per specification to be maintained. Put the charcoal paint on joints. f) Welding to be ensure from all sides as per detailed drawing. g) Make the risers by measuring the required length to connect nearest grid to Equipment. h) Inspection to be done for all welding joints before back filling. EquipmentEarthing: a) GI flats to be bent in proper shape in order to lay on foundation / structures. Holes for bolting to be made in GI Flat with drilling machine. b) Welding of Risers & Flats to be done as per specification. c) Flat to be bolted/connected with structure / equipment. EarthPit/Spikes: a) b) c) d) e) f) g) h)

Marking the location of earth pit as per layout Excavate the pit for the size as per drawing Put the Pipe electrode / Rod Electrode inside pit. Put the layers of charcoal and salt as specified. Make the earthing chamber Fix the clamps for connection with Main Grid and equipment. Put the cover of chamber Connect one side with main grid and other side with the equipment as per drawing.

GISEarthing: a) Ensure that main grid at the periphery of GIS building is done. b) Lay the Earthing rod / lead inside GIS building before casting of GIS foundations. c) Make bending / drilling for risers for connection of GIS equipment d) Risers to be fixed covered inside PVC pipes before concreting e) Connect the risers with equipment with flexible lead / flat as specified. Earthing inside cable trench: a) Lay the MS flat / GI flat on the cable supports b) Weld the flat with cable support angles. c) Connect the flat with Main grid. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 83 of 111

d) Paint the flat as specified. ACCEPTANCE CRITERIA:Conformity to Technical & Standard Specifications. Conformity to the Earthing Layout. Earthing Resistance should be < 1 Ω. SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Since, It involves hot work, Fire Extinguishers and sand buckets to be kept near Gas cutting and welding area. Flash back arrestors must be used for Acetylene Cylinders. Welder must use welding shield and apron.

RECORDS: Earthing checklist(as per FQP). Field Quality Plan (as per Client) Earthing resistance test report MODEOFMEASUREMENT: Quantity in running meter or LS as per customer BOQ FINISHING : All CI covers of Earth Pits to be painted in green and identification number to be given

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 84 of 111

Work Instructions forCabling and Termination SCOPE:- Document describes the Work Instructions for Cable Laying, jointing, glanding and termination of power and control cables for substations ranging from 66 kV to 765 kV ratings. APPLICABILTY:- This procedure is primarily developed for Substation works & applicable to the same, at sites across all locations as per specification. REFERENCEDOCUMENTS:- Following Documents / Drawings / Codes have been referred for the preparation of this procedure:l) IS Code m) IEC Code

RESPONSIBILITY: Responsibility of implementation of this procedure rests with below mentioned officials a) PRIMARY: Site Engineer / Supervisor b) SECONDARY: Project Manager

PREREQUISITE: a) Field Quality Plan (FQP) b) Approved Cable and Termination schedule c) Equipment and Panels installation complete d) Equipment and panels scheme drawings e) Cable trench work complete

EQUIPMENT AND ACCESSORIES: r) s) t) u) v)

Hydra Crane of appropriate capacity Lifting Belts Rollers Spanners and tool box Crimping tool

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 85 of 111

PROCEDURE FOR CABLE LAYING, JOINTING, GLANDING AND TERMINATION :a) Prepare the cable drum schedule and cutting schedule. b) Find out the length required for each run and identify the drum from which cable to be taken as per drum schedule. c) Shift the cable drum from storage area to the work area by using hydra crane. Entire length of cable inside the drum to be tested for its continuity and also for its insulation resistance before using the particular cable drum. d) Use guy rope for tying the packet to avoid any jerk or swing while hydra crane marches from storage area to work area. e) Keep the rollers at regular intervals for pulling the cable. f) Fix the jacks on proper and plane surface. g) Put the cable drum on the jack for rolling. h) Check the jack function by rolling the drum if working properly. i) Start pulling the cable slowly by rolling the drum on jack. j) Stop the drum rolling when required cable length is drawn. k) Cut the cable with help of hack saw. l) Seal both end of cable with water proof sheet / cover if termination is not done immediately. m) Cables to be dressed properly and tags to be put identifying the cable detail. n) Ensure that cable is not twisted. o) Cable end to be prepared for jointing or glanding and termination with the help of knife, sand paper etc. p) Cores to be separated carefully without damaging insulation. Ferrules to be printed and put on cores. q) Glanding rings / checknuts to be put. r) Cable lugs to be crimped with the help of crimping tool (Preferably hydraulic). s) Cable glands to be fixed properly with equipment / panel covers. t) Connection to be done accruing to schematic drawings at both end. u) All the scraps of cables to be removed immediately after termination.

ACCEPTANCECRITERIA:Conformity to Technical & Standard Specifications. Conformity to the Schematic drawing. Conformity to the SLD. System test reports.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 86 of 111

SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. All precautions to be taken as per manufacturers Installation Manual

RECORDS: Cable Laying and Termination Checklist (as per OEM). Field Quality Plan (as per Client) Schematic check Reports MODEOFMEASUREMENT: Quantity in RM / LS as per customer BOQ FINISHING : Phase marking as per approved drawings

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 87 of 111

Work Instructions for Indoor Panel Equipment Erection SCOPE :-Document describes the standard procedure for erection of Indoor equipments of AIS substation like control panel, SAS panel, ACDB, DCDB, Battery Charger etc. APPLICABILTY :-This procedure is primarily developed for Distribution works & applicable to the same, at sites across all locations as per specification. REFERENCE DOCUMENTS:- Following Documents / Drawings / Codes have been referred for the preparation of this procedure:(1) Approved indoor panel erection drawings (2) Field Quality Plan (FQP) (3) IS codes RESPONSIBILITY: Responsibility of implementation of this procedure rest with below mentioned officials a) PRIMARY: Site Engineer/ Supervisor b) SECONDARY: Project Manager

PREREQUISITE: a) Channel fixing on Cable Trench b) Completion of Base frame for Panels c) Internal Finishing of Panel room TOOLS & TACKLES: a) Tool Box ( Annexure –A) b) Fork lift & Crane c) Rollers PROCEDURE FOR PANEL ERECTION :Equipment Erection :a) Lifting the material till the control room by using forklift b) Move the equipment by using rollers till the equipment erection place. c) Before erecting the panels mark the location of each and every panel. Ensure the frames on which the panels will be kept are properly aligned and holes are made as per panel base requirement. d) Ensure the correct direction on which the panels will open. Take proper precaution Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

e) f) g) h) i) j)

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 88 of 111

especially at corners to ensure two panels should open simultaneously. Ensure proper level of base frame so that after erection of panel it should not foul with finished floor level. Refer the individual equipment erection manual before unpacking. Place the equipment on the rollers by using fork lift. As per the approved indoor equipment layout place the equipment properly on its allotted location. This will avoid unnecessary interpanel wiring. Fix the panel with bolt & nuts. Final tightening to be done after checking the vertical & horizontal alignment. Earthing for SAS and communication panels as per earthing recommended drawings. Painting/ Touch up , if required

ACCEPTANCE CRITERIA:(1) Conformity to Technical & Standard Specifications. (2) Verticality as per section drawing (3) Earthing of panels must be done (4) Internal Bus Bar / Wiring connection to be done

SAFETY: (1) Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. (2) Ensure that the material shouldn’t be handled with bare hands, hand gloves shall be used. (3) All precautions to be taken as per manufacturers Installation Manual

RECORDS: Equipment Installation Checklist (as per Client/ Vendor). MODE OF MEASUREMENT: Quantity in Nos as per customer BOQ

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 89 of 111

Checklist Sr. No.

Activity

checklist

1

Check the dimensions of floor opening / base frame w.r.t. OEM / Engg approved dwg.

Ok/Not Ok

2

Shift and install the panel on base frame.

Ok/Not Ok

3

Fix the panel with bolts and provide earthing at two points.

4

Provide aux supply / DC supply as per SLD and ICS issued by Engg.

5

Terminate control and SCADA cables as per ICS and confirm with SCADA team for availability of status and command on SCADA.

6

Conduct SAT as per QAP approved by QAIT. Ensure availability of command and status in CCR server and PSCC.

7

Conduct interlock checks and adopt relay settings.

8

Terminate incomer power cable at DB end.

9

Terminate power cable at source end by taking proper outage of source.

Ok/Not Ok

Ok/Not Ok Ok/Not Ok

Ok/Not Ok

Ok/Not Ok Ok/Not Ok Ok/Not Ok Ok/Not Ok

10

Take both the incomer in service while Bus coupler is open. Check for phasing at both the bus.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 90 of 111

Work Instructions for HVAC Erection (1) SCOPE :Document describes the standard procedure for erection of ventilation and air conditioning system in Sub station. (2) APPLICABILTY:This procedure is primarily developed for Substation works & applicable to the same, at sites across all locations as per specification. (3) REFERENCE DOCUMENTS:Following Documents / Drawings / Codes have been referred for the preparation of this procedure:a) Approved Drawings b) IS Codes c) O&M Manual of suppliers d) Approved FQP

(4) RESPONSIBILITY: Responsibility of implementation of this procedure rest with below mentioned officials a) PRIMARY: Site Supervisor, Site Engineer b) SECONDARY: Project Manager, Safety Engineer, Quality Engineer

(5) PREREQUISITE: a) Completion of associated civil works for erection of equipments. b) Availability of complete system at site.

(6) TOOLS & TACKLES: a) Lifting Tools & Tackles b) Pipe Rollers d) Electrician Toolbox Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 91 of 111

(7) PROCEDURE FOR EQUIPMENT :(7.1) Equipment Erection :a) Before erecting obtain reflected ceiling plan (RCP) from concerned agency. RCP indicates location of HVAC, light fittings, smoke detector and false ceiling. b) Check that no system interferes with other. c) Prepare ducts as per approved thickness and cross sectional area. d) Make support arrangement for ducts on the wall as per approved dwg. e) Install the ducts and fans at locations shown on dwg. f) Make the duct joints with proper insulation material. g) Connect power supply to the fans and compressor units from ACDB / as per approved drawings. h) Start the fans / compressor and check for any leakage at the joints.

(7.2) FINISHING : The joints are to be proper and there should not be any leakage. The drain pipe for water condensation to be properly routed to outside of the building.

(8) ACCEPTANCE CRITERIA:Conformity to Technical & Standard Specifications. The temperature and humidity after 24 hrs of continuous running of the system are to be as per approved specification.

(9) SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe, Hand gloves, goggles, LOTO) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Ensure that the material shouldn’t be handled with bare hands, hand gloves shall be used. All precautions to be taken as per manufacturers Installation Manual

(10) RECORDS: Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 92 of 111

Equipment Installation Checklist (as per Client). Field Quality Plan (as per Client)

(11) PHOTOS :-

(12) MODE OF MEASUREMENT: Quantity in Nos as per customer BOQ

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 93 of 111

Checklist

Checklist For HVAC System Check Point 1 2

3

4 5 6 7

Remarks

Check that no system interferes with other.

Ok / Not Ok

Check the tightness of all hardware’s

Ok / Not Ok

Check the insulation thickness of the duct (in case of air conditioning system)

Ok / Not Ok

Ensure the earthing connections at two points.

Ok / Not Ok

Check the cross sectional area of ducting system

Ok / Not Ok

Check the joints for any leakage

Ok / Not Ok

Check the direction of rotation of compressor motor / fan motor.

Ok / Not Ok

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 94 of 111

Work Instructionsfor Structure(Tower & Gantry)Erection SCOPE :Document describes the standard procedure for erection of Structure ( Towers & beams) from 66 kV to 765 kV switchyard .

APPLICABILTY :This procedure is primarily developed for Distribution works & applicable to the same, at sites across all locations as per specification.

REFERENCE DOCUMENTS :Following Documents / Drawings / Codes have been referred for the preparation of this procedure:a)IS Codes b) Field Quality Plan (FQP) c) Drawings and bills of material of structures / beams / equipment structures.

RESPONSIBILITY: Responsibility of implementation of this procedure rest with below mentioned officials a) PRIMARY: Site Engineer / Supervisor b) SECONDARY: Project Manager

PREREQUISITE: A) Complete Foundation of all towers with Bolt fixing. B) Lubrication / Covering of Foundation bolt.

TOOLS & TACKLES: a) Lifting Tools & Tackles b) Crane c) Templates of structures. d) T & P such as levelling instruments, tackles, spanners, jacks, winches, ropes, derrick, etc. e) Foundation Bolts

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 95 of 111

Types of Towers:Sl . A.

Name of Structure

1

7CF

2 3 4 5 6 7 8 B. 1 2 3 4 5 6 7 8 9 C. 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2

7CG 7BL 7GWCF 7BK 7BM 7BN 7GWCG TA TB TE TG TH TI TK G1 G2

Type of Structure 765 kV Structures: Tower Type Tower Type Beam Beam Beam Beam Beam Beam 400 kV Structures:

Height of Column (Mtr.)

27 25.3 (Width)

20 15 20.0 / 14.5 and 9.5

Beam Beam 220 kV Structures:

10.0 / 9.5 15.0 / 9.5 16.6 (Width)

CA CB CB W/O Peak CC CD CTA CTB CTC CTD

16 12 16.0 / 11.5 and 7.5

CTE

7.5

CTG

3

CTH

10.0 (Width)

8 12.0 / 7.5 12.2 (Width) 2.5

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 96 of 111

Equipment Installation 1 3 1 4 1 5 1 6 1 7

CTI CTI W/O Peak B1

Beam

BG1

Beam

Lighting Mast

Tower

ERECTION PROCEDURE FOR TOWER & BEAM SETTING OF STUB / FOUNDATION BOLTS, LEVELLING AND GROUTING: (1) In case of structures with foundation bolts, the template, along with the foundation bolts tightened on it with nuts on both sides, shall be placed on the foundation. The length of the foundation bolts above the template shall be sufficient so that all parts of the base plate assembly of the structure, washers, nuts and lock nuts can be tightened fully and 2 – 3 threads are left above the lock nut. (2) The template is levelled & centered with reference to its location on the foundation. The foundation bolts shall thereafter be grouted ensuring that there is no displacement during the placing of the concrete and use of vibrator. To Be Checked: a) Distance of centre line of the structure from the centre line of other structures or from a reference point. b) Centre to centre distance between structures, particularly structures which are to be connected together, for example, by a common beam Method of Erection: There are mainly two methods of erection of structures, which are as below: (1) Ground assembly method a) This method is used for erection of equipment structures and is the preferred method for erection of sub station structures when crane facility is available. b) This method consists of assembling the structure on the ground and erecting it as a complete unit. c) The complete structure is assembled in a horizontal position near its location. On sloping or uneven ground, suitable packing is provided in the lower level area before or during Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 97 of 111

assembly, as required, to eliminate / minimize stress on the structure members. d) After the assembly is complete, the structure is picked up from the ground with the help of a crane and set on its foundation.

(2) Built up method or Piecemeal method: (a) This method is used for large and heavy structures when crane facility is not available. (b) This Method consists of erecting the structure member by member. The str. members are kept on ground serially according to erection sequence so that they can be sent up conveniently. (c) The erection progresses from the bottom upwards. The four main corner leg members of the first section of the structure are first erected. (d) The cross bracings of the first section are raised one by one and bolted to the already erected corner leg angles. If these have been assembled on the ground, then they are lifted up as a unit. (e) For assembling the second section of the structure, a derrick is placed on one of the Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 98 of 111

corner legs. This derrick is used for raising parts of second section. The leg members and bracings of this section are then hoisted and assembled. (f) The derrick is then shifted to the corner leg members on the top of second section to raise the parts of third section of the structure in position for assembly. The derrick is thus moved up as the structure grows. This process is continued till the complete structure is erected.

(3) ERECTION OF BEAMS: (a) The two faces of the beam are assembled on the ground. (b) Each face of the beam is raised with the help of crane or using derricks which are placed on the top of the already erected structures on both the sides of the beam. Single or multi – way pulleys with polypropylene / steel ropes are used as per load requirement. The ends of the beam are connected to the column as per fixing arrangement provided on the columns. c) The bracings of the upper and lower faces of the beam are then raised up and fitted. d) The columns shall be truly vertical and the beams truly horizontal after erection. Measures taken to bring the column to verticality and beam to horizontality should not result in strain on the structure members so as to cause distortion / bending of the members. e) The work of erection of beams on erected columns and erection of equipment on erected structures shall not be taken up until these have been checked for tightening of the bolts & nuts. All bolted connections shall be well tightened using spring washers & then punched at three points on the circumference of the bolt. All the tightening must be checked with the help of Torque Wrench with specified values.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 99 of 111

ACCEPTANCE CRITERIA :Conformity to Technical & Standard Specifications. Erection as per BOM & drawings Verticality as per section drawing

SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Ensure that the material shouldn’t be handled with bare hands, hand gloves shall be used. When Working on height , The nuts & Bolts must be supplied in gunny bags with rope.

RECORDS: Tower & Beam Installation Checklist (as per Client).

MODE OF MEASUREMENT: Quantity in Nos as per customer BOQ

FINISHING : Tightening of nuts & bolts after fixing of beams. Phase Marking on towers Danger Plate Installation on Towers

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 100 of 111

Checklist

Checklist For Tower, Gantry, Beam Check Point 1 2 3 4 5 6 7

Remarks

Check whether all H/W are used as per approved dwg.

Ok / Not Ok

Check the tightness of all hardwares

Ok / Not Ok

Check the alignment of structure with spirit level

Ok / Not Ok

Ensure the earthing connections at two points.

Ok / Not Ok

Ensure the lightning spikes are installed as per approved dwg.

Ok / Not Ok

Ensure earthing strips are painted as per specifications

Ok / Not Ok

Ensure phase markings

Ok / Not Ok

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 101 of 111

Work Instructions for Stringing , Jumpering , Earthwire, Al. Tube erection SCOPE :Document describes the standard procedure for Stringing, Jumpering, Earthwire, Al. tube erection from 66 kV to 765 kV switchyard .

APPLICABILTY :This procedure is primarily developed for Distribution works & applicable to the same, at sites across all locations as per specification.

REFERENCE DOCUMENTS:Following Documents / Drawings / Codes have been referred for the preparation of this procedure:a)IS Codes b)Field Quality Plan (FQP) c) Approved Sag Tension calculations & drawing d) Approved EKD .

RESPONSIBILITY: Responsibility of implementation of this procedure rest with below mentioned officials a) PRIMARY: Site Engineer / Supervisor b) SECONDARY: Project Manager

PREREQUISITE: a) Tower & Gantry Erection b) Supply of Single & double Hardware fittings, Disc Insulator Strings drawings , 4” IPS Tube c) Shield wire Erection

EQUIPMENT AND ACCESSORIES: a) Tested Tools & Tackles b) Spanners, jacks, winches, ropes, D-shackles, c) Electrician Toolbox Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 102 of 111

ERECTION PROCEDURE :(1) Handling of Material A) The conductor shall be handled with care to prevent scratches on it or damage to the strands of the conductor. When the conductor is to be taken from drums, small lengths can be unwound from the drum. For longer lengths, the conductor drum shall be placed on a turn table or jacked up on a suitable size of steel shaft. The conductor shall be paid out in a manner so that there are no scratches or damages caused to the conductor due to rubbing on the sides of the drum.

B) Disc insulators shall be cleaned and examined for any cracks / chipping, etc. Disc insulators having any hair cracks or chipping or defective glazing or any other defect shall not be used ERECTION PROCEDURE:(1) STRINGING (2) EARTHWIRE (3) JUMPERING (4) Al. TUBE WELDING & ERECTION

(1) STRINGING OF CONDUCTOR BUS BARS:A) The disc insulators shall be assembled on the ground to form the suspension and tension strings as given below. Suspension String Tension String System Voltage E&M E&M No. Nos. Strength (kN) Nos. Strength (kN) 1. 765kV (Anti fog Type) 47 2 x 47 210 210 2. 400 kV (Anti – fog type) 25 120 2 × 25 120 3. 220 kV at 400 kV GSS (Anti–fog type) 15 70 2 × 15 70 4. 220 kV 13 70 14 120 5. 132 kV 9 45 10 120 Sl.

B) After assembly of the strings, the mouth of the W – clips / R – clips shall be widened to prevent any inadvertent removal during service. C) The suspension and tension hardware shall be assembled as per their respective drawings and the disc insulator string shall be fitted in the requisite portion of the hardware assembly Each suspension & Tension hardware set shall comprise of the following components

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 103 of 111

D) Single suspension & Double Suspension hardware must comprise of the following components

(1) Yoke Plate (2) Socket Clevis (3) Clevis Eye (4) Suspension Clamp (5) Ball Eye (6) Arching Horn(ball & rod) (7) Turn Buckle

E) Single Tension & Double Tension hardware must comprise of the following components:

(1) Turnbuckle (2) Yoke Plate (3) Clevis Clevis (4) Corona ring (5) Socket Clevis (6)Tension Clamp (7) Extension Link (8) Anchor Shackles (9) Arching Horn

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 104 of 111

(F) For stringing of bus bars, the conductor shall be fixed and tightened in the clamp of the tension hardware on one side of the bus. Thereafter, the complete hardware assembly with the conductor shall be hoisted up and fixed on the beam at this end. Sagging arrangement shall be made on the other Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 105 of 111

end of the bus and the conductor shall be tensioned. (G) Measurement of length of conductor required for the bus shall be made thereafter and the conductor shall be released so that it returns to the ground. The conductor shall be cut to the marked length after deducting the length of the tension hardware with insulators and fixed on the clamps of the tension hardware. The conductor along with tension hardware set shall then be again pulled up and connected to the beam (H) The spacers shall be fitted on the twin and quadruple conductor bus bars at the spacing shown in the drawing.The spacers shall also be provided at points where jumpers are takenfrom the bus bar using T – clamps and / or P. G. clamps. Spacers are not used at jumper points in case T – Spacers are used for taking jumpers from multi conductor bus bars

(2) Earthwire Stringing (A) Sub Station is shielded against direct lightning strokes by overhead shield wire / earth wire. The methodology followed for system up to 400 kV is by suitable placement of earth wire so as to provide coverage to all the station equipment. Generally, an angle of shield of 60° for zones covered by two or more wires and 45° for single wire is considered adequate. (B) The earth wire shall be strung from one peak to another peak of the structures as per layout of the GSS (C) The shield / earth wire shall be fitted and tightened in the clamp of the tension hardware on one side. Thereafter, the complete hardware assembly along with the shield / earth wire shall be hoisted up and fixed on the peak of the structure at one end. (D) Adjustment of tension in the earth wire may be done, if required, to ensure equal sag of all the earth wires in adjacent or parallel sections.

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 106 of 111

(3) JUMPERING OF CONDUCTORS: The jumpers connecting different sections of the bus bars as well as those connecting equipment to bus bars shall be of Y – type. (A) For making Y – type jumpers, the jumper conductor(s) shall be first connected to the bus bar conductor(s) using T – Clamp / Spacer T – Clamp which is suitable for clamping the respective conductors, i.e., bus bar conductor(s) and the jumper conductor(s). Thereafter, the bus bar conductor(s) shall be again connected with the jumper conductor(s) using properly curved & shaped Y – conductor(s) and 2 nos. PG – clamps as shown in the diagram above. (B) The jumpering between equipment shall be done with single / twin / quadruple conductors as per the terminal connectors provided on the equipment.

JUMPERING OF BUS BARS: (A) For jumpering of different sections of bus bars on the beam, the suspension hardware set along with disc insulators shall first be hoisted and fitted on the beam. (B) Conductor of approximately length required for the jumper shall be cut and straightened so that kinks are removed. This shall be connected to the bus bar conductor on one side of the beam after Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 107 of 111

taking into consideration the natural curve of the conductor. (C) This shall then be passed through the clamps on the suspension hardware so that the proper curve is obtained. The other end of the conductor shall then be taken up to the bus bar conductor on the other side and measurement of the length shall be taken. The conductor shall be cut to the appropriate length and then connected to the bus bar conductor on the other side. The length of the conductor used and its natural curve should be such that a neat and proper curve is obtained in the jumper without any kinks or bends. The clamp of the suspension hardware shall then be tightened after ensuring proportional lengths of the conductor on both the sides of the beam.

JUMPERING BETWEEN EQUIPMENTS: (A) The distance between terminal connector of one equipment and terminal connector of other equipment is first measured. (B)The appropriate length of the conductor shall be cut and then straightened so that curves and kinks are removed. (C) The jumper conductor shall then be connected to the terminal connectors of both the equipments and straightened or shaped as per site condition to give a neat and proper look. (D) Vertically supported insulators of equipments and Post Insulators should be checked for verticality again after jumpering on both sides, and corrected, if required.

(4) Al. TUBE WELDING & ERECTION The following material / T&P / consumables are required for carrying out the work of welding of aluminium pipes / couplers / connectors. (1) T.I.G. / M.I.G. welding set with Tungsten wire. (2) Argon Gas. (3) Oxy – acetylene torch with accessories or blow lamp. (4) Filler wire. (5) Water tank for welding. (6) Tools such as chipping hammer, files, sand paper, steel wire brush, wind screen, blue glass slits, hacksaw frame, blades, power saw, etc. (7) Cleaner, dye and developer and all safety equipments Welding Procedure:The joints / couplers shall be got machined in order to perfectly match their inner / outer diameter with the aluminium pipe. All the surfaces to be welded must be thoroughly cleaned with Acetone or Alcohol to remove any oxide layer and foreign contaminants present on it to attain a fast joint and avoid porosity. In addition, a stainless steel wire brush shall be used for cleaning the surfaces. Before fitting the straight run coupler, the edges of the pipes to be welded for straight joints are to be beveled at an angle of 45° with a flat file to make a V – groove at the ends of joint. In cases where outer diameter of sleeve does not match the inner diameter of pipe, the sleeve shall be got turned to match the inner diameter of the pipe. Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 108 of 111

The straight run coupler is then to be pressed and both the pipes are pushed on to it till their ends come near the centre of the coupler. The centering pin of the coupler is fitted in the hole provided for it and the pipe ends are brought together until they touch the centering pin. The straight run coupler is then split open so that it fits tightly on the inner surface of the pipe. It is held in this position till at least 25% of the welding of the coupler has been done. The welding of the joint is then done till the V – groove between the pipes is filled with the fused metal

4” IPS Aluminium Tube Joint Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 109 of 111

(1) T.I.G (TUNGSTEN INERT GAS) welding utilizes high frequency A.C. generating set and welding torch having tungsten wire with outflow of inert gas like Argon, etc. M.I.G. (METAL INERT GAS) welding process is used as an alternative when T.I.G. welding is not available (2) To avoid cracks in the joints after welding, the surface should be preheated uniformly with oxy – acetylene torch or blow lamp. (3) During welding, continuous flow of inert gas shall be maintained over the joint as well as inside the pipe to avoid oxidation on the inside surface. This flow of inert gas on joint should continue for at least 15 seconds after the welding of joint is completed (4) All the welding at a joint must be in one layer. If more layers are required at the joint, every bottom layer shall be cleaned with wire brush and checked for cracks before starting welding of the second layer. If any crack is observed, the whole layer shall be chipped off and refilled. (5) The joint, when completed, must be filed smooth with a wood file and fine sand paper. (6) Wind shield shall be used, if required, for protecting the joints from the blowing wind which may take away heat and inert gas flow at the surface of joints. (7) Every care shall be taken for preventing the scratches and roughness on the aluminum surface. (8) The welding should be got done so that molten mass is filled in gaps and no cracks or imperfections are present in joints. Unacceptable joints shall be chipped off for re – welding. (9) Each and every joint shall be subjected to: a) Physical examination. b) Liquid penetration test. (10) For liquid penetration test, the following three items are required: c) Cleaner for cleaning the joint. d) Red dye for spraying on the cleaned joint which will penetrate into the cracks, if any. e) White developer to be sprayed on the joint that will draw the red dye from the cracks and make these cracks visible, if present.

ERECTION OF ALUMINIUM PIPE BUS BAR: (1) Aluminium pipes are used for 400 kV and 33 kV bus bar jumpers and interconnections at 400 kV GSS. The diameter of the pipes is 114.30 mm and 73.03 mm for 400 kV and 33 kV respectively. (2) The height of the 400 kV main bus is 8 meters & 10 meters and that of jumpers is generally 8 meters, 10 meters & 13 meters. (3) Fixed, sliding and expansion type clamps are fitted on the already erected post insulators as per the drawing. (4) The standard length of aluminium pipes is generally 6.0 to 7.0 meters. To reduce welding work at the bus height in case longer lengths are required, a maximum of 4 to 5 lengths of aluminium pipes Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 110 of 111

may be welded together on the ground using straight run couplers. The pipe length is then lifted and erected on the post insulators. (5) If required for the bus length, the already erected pipe lengths are welded together at the bus height. (6) In case the bus height changes, then the pipes at the different levels are welded together with a piece of pipe using appropriate angular couplers (90° or 110° or 135°) as per drawing by client.

ACCEPTANCE CRITERIA :Conformity to Technical & Standard Specifications. All the Hardware fitting, conductor, jumpering erection as per EKD Verticality as per section drawing

SAFETY: Use of safety PPEs like (Safety Belt, Helmet, Safety Shoe/, Hand gloves) is must. Site Engineer and supervisor should be ensuring that all workmen should wear the said PPE’s before starting work. Ensure that the material shouldn’t be handled with bare hands, hand gloves shall be used. All precautions to be taken as per manufacturers Installation Manual

RECORDS:

Equipment Installation Checklist (as per Client). Field Quality Plan (as per Client)

MODE OF MEASUREMENT: Quantity in Nos as per customer BOQ

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel

Work Instructions Equipment Installation

Document No KEC/SS/SOP/E/005 Date & Rev No 29.6.16 /00 Sheet No Page 111 of 111

Checklist

Checklist for Stringing, jumpering. Check Point 1 2 3 4 5 6 7

Remarks

Check the number and type of insulators as per EKD

OK / Not Ok

Check the number of spacers as per EKD

OK / Not Ok

Check the sectional clearance from nearby structures

OK / Not Ok

Check the span length

OK / Not Ok

Check the die of hydraulic crimping tool as per requirement

OK / Not Ok

Check the tightness of all connectors

OK / Not Ok

Check the phase to phase clearance

OK / Not Ok

Prepared By – Vishal Sharma, Soumya Ranjan, Vivek Gupta,Reviewed by – Sukesh Veauli,SanjayGupta, Vimal Gupta , Approved By- Rajinder Gupta, Kaushal Kodesia, Swamy Gabriel