NATIONAL TRANSMISSION AND DESPATCH COMPANY

LTD

STANDARD OPERATING PROCEDURES (SOP)

FOR
GRID SYSTEM OPERATION AND MAINTENANCE

1) GRID STATION EQUIPMENT

2) PROTECTION AND INSTRUMENTATION
3) TRANSMISSION LINES

TECHNICAL SERVICES GROUP (TSG) LAHORE

JUNE 2013 SOP (M)-TSG-001/R1

TABLE OF CONTENTS
Sr. Description Page

1
No. No.
1 Introduction 4
2 Maintenance of Grid System 7
2.1 General 8
2.2 Schedule Maintenance 8
2.3 Non Schedule Maintenance 8
2.4 Preventive Maintenance Program 8
2.5 Inspection 9
2.6 General Terms Used in Maintenance Work 9
3 Job Planning 14
3.1 Description of steps involved in Job Planning 15
4 Job Safety Awareness and Safety Code 19
4.1 Basic Safety Guide Lines 19
5 Maintenance Schedule and Checks of Grid Station 22
Equipment
5.1 Maintenance Schedule and checks of Transformers 23
5.2 Maintenance Schedule and checks of Circuit Breakers 32
5.3 Maintenance Schedule and checks of Isolators 38
5.4 Maintenance Schedule and checks of C.Ts 42
5.5 Maintenance Schedule and checks of P.Ts 45
5.6 Maintenance Schedule and checks of CVTs 48
5.7 Maintenance Schedule and checks of Surge Arresters 51
5.8 Maintenance Schedule and checks of Bus Bars 54
5.9 Maintenance Schedule and checks of Grounding System 57
5.10 Maintenance Schedule and checks of 11KV CBs 60
5.11 Maintenance Schedule and checks of DC Batteries 64
5.12 Maintenance Schedule and checks of DC Battery Chargers 67
5.13 Maintenance Schedule and checks of Auxiliary Supply System 70
5.14 Maintenance Schedule and checks of Shunt Reactors 73
5.15 Maintenance Schedule and checks of GIS 78
5.16 Maintenance Schedule and checks of Power & Control Cables 84
5.17 Maintenance Schedule and checks of Shunt Capacitor Banks 87
5.18 Maintenance Schedule and checks of Fire Detection & Fire 90
Fighting Equipment
5.19 Maintenance Schedule and checks for work support facilities at 92
Control Building
5.20 Maintenance Schedule and checks for work support facilities at 95
Outdoor Switch Yard Area
5.21 Maintenance Schedule and checks for living support facilities 96
at Residential Colony of Grid Station
6 Maintenance Schedule and Checks of Protection and 98
Instrumentation (P&I)

2
 6.1 Maintenance Schedule and checks of Control Panels 100
6.2 Maintenance Schedule and checks of Protection Relay Panels 102
6.3 Maintenance Schedule and checks of Transmission Line 104
Protection
6.4 Maintenance Schedule and checks of Transformer Protection 105
6.5 Maintenance Schedule and checks of Miscellaneous 107
Protection Relays
7 Maintenance Schedule and Checks of Transmission Lines 109
8 Technical Directive for Transmission Lines 113
9 Reference Data for Interpretation of Test Results 116
10 Operation of Grid System 151
10.1 Introduction 152
10.2 General Provisions 153
10.3 NPCC SOP for System Reliability and security 156
10.4 NPCC Contingency Plan for Black Start of Tarbela Power 157
Station
10.5 Parallel Operation of Transformers 159
10.6 Loading of Transformers 160
10.7 Measures to Minimize Damages due to Fire Incidents of 166
Transformers
10.8 Criteria for Re-switching of Transformers after their outages 167
on faults
11 General Applications 169
11.1 Device Function Numbers 169
11.2 Transformers: Important Definitions and Characteristics 178
Quantities
11.3 Circuit Breakers: Classes of Circuit Breakers, Important 195
Definitions, Operating Time and Characteristic Quantities
11.4 Properties of Insulating Oil, their Significance and Test 203
Methods (IEC 60296 – 2003)
11.5 Treatment of Oil 209
12 Revision Table for SOP (M) 213
13 References 214

1. INTRODUCTION

To keep the electrical power system in safe, stable and reliable operating
condition, it is necessary that the system should be operated and maintained
properly to retain its each component in or restore it to a state in which it can
perform a required function.

3
Maintenance has become nowadays an important factor due to many reasons.
Economic and legal considerations are among the most significant, for example
extending the service life, reducing life cycle costs, reducing downtimes, safety
aspects and environmental protection regulations. In addition to the purchase
costs, the profitability of switchgear and control-gear in both the high and low
voltage systems depends above all on the calculated operating costs for the
entire service life. Therefore, to meet with the current requirements of up-
gradations in the electro-technical technologies, emerging modern trends of
operation and maintenance, technical standards/specifications and safety
awareness this new edition of Standard Operating Procedure (SOP) has been
compiled.

This booklet of SOP covers all the operation and maintenance requirements of
grid system of GSO departments of NTDC and DISCOS in all the three main
fields of grid system:

- Grid Station Equipment,

- Protection and Instrumentation,

- Transmission Lines.

A view of 220kV switchyard of 220kV G/S NTDC NKLP Lahore

4
 A view of protection relay room at 220kV G/S NKLP Lahore

A view of 220kV transmission lines entering 220kV G/S NKLP Lahore

The scope of operation and maintenance work relevant to the above mentioned
main fields including the other allied works have been described in terms of
implementation frequency and schedules, work activities, testing, etc. In simple
words this SOP describes that what to do and when to do but for how to do, the

5
work procedures have been described in skill enhancement training course
books of TSG training program. The relevant reference data for comparison and
interpretation of different operating conditions and test results has also been
included in the booklet.
Safety and health of the workers has a paramount importance in implementation
of the SOP. Lack of Safety awareness, Un-safe acts and Un-safe working
conditions, etc. always result into accidents and damages either to the workers
or the equipment. It is essential that while on work each worker must follow the
safe working methods and procedures as the life or loss he saved could very
well be his own. The safety instructions as per Power Safety Codes of NTDC
and DISCOs shall be followed by the each individual employee while on work
at the company premises.
The contents herein the booklet are in-line with the WAPDA/PEPCO technical
specifications, NTDC Grid Code, IEC standards and the recommendations of
the manufacturers dealing with the grid system equipment and other hardware.
However, deviation to these instructions and guidelines is permissible if the
more effective alternatives are implemented.

2. MAINTENANCE OF GRID SYSTEM

6
2.1 GENERAL
The word “maintenance” in encountered frequently, though it is used with
different meanings. Its overall concept includes inspections, scheduled
maintenance, non-scheduled maintenance and corrective measures. As per IEC
standard, maintenance is the combination of all technical and administrative
actions, including supervision actions, intended to retain an item in, or restore it
to, a state in which it can perform a required function. The proper maintenance
also ensures correct operation of grid station equipment permanently over its
design life, even longer if it is justified economically and technically. Generally
the maintenance work is categorized as scheduled maintenance and non-
scheduled maintenance.

2.2 SCHEDULED MAINTENANCE

The preventive maintenance carried out in accordance with an established time
schedule. Scheduled maintenance covers all measures aimed at retaining the
design state of the technical equipment belonging to a system and may take
place as and when required or in regular/fixed interval of time. Scheduled
maintenance includes such activities as cleaning and washing, conservation,
lubrication and where necessary amending or replacing parts subject to wear
and tear. Scheduled maintenance also involves preparation of maintenance
schedules, carrying out the specified work and dealing with feedback relating to
this work.

2.3 NON-SCHEDULED MAINTENANCE

7
Non-scheduled or corrective or emergency maintenance is often not in
accordance with an established time schedule and usually needs as result of
malfunction or unexpected defect. Non-scheduled maintenance covers all
measures aimed at restoring the designed state of the technical equipment
belonging to a system. Repair work and part replacement are typical types of
corrective maintenance. It also involves planning, handling requests for
performing/checking and evaluating the necessary measures (functional tests
etc.). It is worth mentioning that an effective preventive maintenance program
always minimizes emergency maintenance breakdowns and damages of grid
station equipment.

2.4 PREVENTIVE MAINTENANCE PROGRAM

The responsibility of carrying out maintenance work always lies with the owner
of the equipment, e.g. NTDC/DISCOs. The company is under an obligation to
observe all the valid safety rules, technical rules/procedures and specifications.
The specifications of maintenance work must be based on certain requirements,
standards, specifications and the guidelines supplied by the manufacturer, local
experience, etc.

2.4.1 MAINTENANCE INTERVALS

Generally following are the three main criteria which determine the time period
or intervals to carry out the preventive maintenance on grid system equipment:

- The recommended time and service period,

- The number of mechanical operations,
- The number of short circuit current disconnections or the total number of
breaking currents.
It is a universal practice that most of the maintenance work is carried out on the
criteria of recommended time periods of service life of the equipment (daily,
weekly, monthly, quarterly, annually, 5 to 10 yearly, 20 yearly, etc.). The time
period are specified on the bases of the recommendations of the manufacturers
and the local experiences. The local experiences include administrative rules &
regulations, service conditions, the available resources, other influencing
factors, etc. Maintenance, on the criteria of numbers of mechanical operations
or electrical switching operations, is carried out rarely. Whether, visual
inspections or scheduled or non-scheduled maintenance all contribute to a
preventive maintenance program.

2.5 INSPECTION
Visual inspection/investigation of the principal features of the switchgear &
control-gear and other equipment in service belonging to a system is carried out,
without dismantling, to evaluate the actual status. This investigation is generally
directed toward pressures (air, gases) and / or levels of fluids (insulating oil,

8
lubricating oil, hydraulic oil), tightness, position of relays, pollution of
insulating parts, but actions such as lubricating, cleaning, washing etc. which
can be carried out with the switchgear and control-gear in service are also
included. Inspections are also described as walk around visual inspection from
ground level keeping in view the safe limits of approaches. Shutdown of the
equipment is not involved normally. On the bases of inspection data, short-term
and long-term work program for carrying out preventive maintenance are
prepared to meet with the best possible level of operational availability and
reliability of the grids system.

2.6 GENERAL TERMS USED IN MAINTENANCE WORK

Overhaul
Work done with the objective of repairing or replacing parts which are found to
be out of tolerance by inspection, tests, examination, or as required by
manufacturer’s maintenance manual, in order to restore the component and / or
the switchgear and control-gear to an acceptable condition. Overhauling can be
categorized as minor overhauling and major overhauling depending upon the
specific instructions of the manufacturer and / or local experience and policy of
the company.

Minor Overhaul
Minor overhauling of the equipment is a sort of detailed/expanded visual
inspection for which shutdown is normally involved. Routine functional tests
are performed to assess the operational condition and reliability of the
equipment. Dismantling of the equipment is normally not involved, hence no
need of spare parts. The time period of one to two years of service life is
considered as normal frequency for minor overhauling.

Major Overhaul
Major overhauling of the equipment involves dismantling into sub-assemblies
and detailed examination of the component parts and measurements of the wear
tear effects. Replacement of certain parts is essential such as tightness system
gaskets, O-rings etc. The time period of five to twenty years of service life is
considered as normal frequency for major overhauling. Shutdown of the
equipment is an essential requirement.

Diagnostic Tests
These tests are comparative tests of the characteristic parameters of switchgear
& control-gear and other equipment to verify that they perform their functions,
by measuring one or more of these parameters.
Note. The test results from diagnostic tests can lead to the decision to carry out
overhaul.

9
Down Time
This is the time interval during which an item is in a down state (not
functioning).

Examination
Inspection with the addition of partial dismantling, as required, supplemented
by means such as measurements and non-destructive tests in order to reliably
evaluate the condition of the switchgear and control-gear.

Defect
An imperfection in the state of an item (or inherent weakness) which can result
in one or more failures of the item itself, or of another item under the specific
service or environmental or maintenance conditions, for a stated period of time.

Failure
The termination of the ability of an item to perform a required function is called
failure.

Note. 1 After “failure” the item has a fault.

Note. 2 “Failure” is an event, as distinguished from “fault”, which is a state.

Note. 3 This concept of “failure” as defined does not apply to items consisting
of software only.

Minor Failure (of switchgear & control-gear and other equipment)

Any failure of a constructional element or a sub assembly which does not cause
a major failure is referred as minor failure.

Major Failure (of switchgear & control-gear and other equipment)

Failure of switchgear & control-gear and other equipment which causes the
blockage of one or more of its fundamental functions is referred as major
failure. A major failure will result in an immediate change in the system
operating conditions, e.g. the backup protective equipment will be required to
remove the fault, or will result in mandatory removal from service within 30
minutes for unscheduled maintenance.

Disruptive Discharge
Phenomenon associated with the failure of insulation under electric stress, in
which the discharge completely bridges the insulation under test, reducing the
voltage between the electrodes to zero or nearly to zero.

10
Note.1 This term applies to “discharges” in solid, liquid and gaseous dielectrics
and to combinations of these.

Note. 2 A “disruptive discharge” in a solid dielectric produces permanent loss

of dielectric strength (non-self-restoring insulation); in a liquid or gaseous
dielectric, the loss may be only temporary (self-restoring insulation).

Spark-over
A disruptive discharge which occurs in a gaseous or liquid dielectric is referred
as spark over.

Flashover
A disruptive discharge which occurs over the surface of a solid dielectric in a
gaseous or liquid medium is referred as flashover.

Puncture
A disruptive discharge which occurs through a solid dielectric is referred as
puncture.

Partial Discharge (PD)

Localized electrical discharge that only partially bridges the insulation between
conductors and which can or cannot occur adjacent to a conductor.

Note. 1 ‘Partial discharge’ is in general a consequence of local electrical stress

concentrations in the insulation or on the surface of the insulation. Generally,
such discharges appear as pulses having duration of much less than one µs.
More continuous forms can, however, occurs, such as the so-called pulse-less
discharges in gaseous dielectric.

Note. 2 ‘Corona’ is a form of partial discharge that occurs in gaseous medium

around conductors which are remote from solid or liquid insulations. “Corona”
should be used as a general term for all forms of PD.

Corona
Corona discharge is defined as a luminous discharge due to ionization of air
surrounding a conductor caused by a voltage gradient exceeding a certain value.
The ionization takes place in a zone which is a very thin circumferential layer
(not more than 2 cm) surrounding the conductor surface. Corona discharge
forms at the surface of transmission line conductor when the electric field
intensity on the conductor surface exceeds the breakdown strength of air. If the
voltage is high, the surface stress may reach a value at which the air

11
breakdowns and become a conductor. The conducting layer of air forms part of
conductor and the radius of the conductor increases due to which the surface
stress decreases. If the spacing between conductors is small, the corona
discharge may bridge the conductors and cause flash over. The corona discharge
is accompanied by the “faint glow” and a hissing noise.

External Insulation
The distances in air and the surfaces in contact with open air of solid insulation
of equipment, which are subject to dielectric stresses and to the effects of
atmospheric and other external conditions such as pollution, humidity, vermin,
etc. is referred as external insulation.

Internal Insulation
The internal solid, liquid or gaseous parts of the insulation of equipment, which
are protected from the effects of atmospheric and other external conditions is
referred as internal insulation.

Self-restoring Insulation
Insulation which completely recovers its insulating properties after a disruptive
discharge is referred as self-restoring insulation.

Non Self-restoring Insulation

Insulation which loses its insulating properties or does not recover them
completely after a disruptive discharge is referred as non-self-restoring
insulation.

Degree of Protection (IP Code)

A coding system to indicate the degrees of protection provided by an enclosure
against access to hazardous parts, ingress of solid foreign objects, ingress of
water and to give additional information in connection with such protection.
The classification of degree of protections is identified by a symbol comprising
two letters IP (International Protection) which always remain the same and two
digits indicating the degree of protection e.g. IP-44 (Reference IEC 60529, VDE
0470 Part-1 and EN 60529).

12
3. JOB PLANNING
Jobs are executed more efficiently and effectively when they are planned well
and all concerned know what is expected. The following steps and guidelines
should be considered for planning the routine maintenance jobs. The emergency
maintenance jobs (such as trouble shooting, repairing, etc.) are non-scheduled,
however, the procedure/steps followed in planning a scheduled work and the
experience gained thereof is equally applicable in handling emergencies.
Special attention should be given to the safety requirements.

1) Follow the approved work program.

2) Arrange the maintenance procedures.
3) Arrange equipment manual and drawings.
4) Arrange previous maintenance records.
5) Arrange the spare parts required.
6) Arrange T & P and test equipment needed.
7) Estimate and arrange to meet the expenditure involved.
8) Estimate the number of man hours and the length of .time required to
complete the job.
9) Arrange to get co-ordination of the other work groups ( such as Grid
maintenance, P&I, T/L, etc.) if needed.
10) Arrange shut down of the equipment to be worked on if needed (refer procedure
for PTW).
11) Inspect job site to look for:

11.1) Hazards.
11.2) What equipment are to be de-energized to get safe working clearances?
11.3) Isolation points & grounding facilities
11.4) What types of aerial devices (i.e. scaffold, bucket truck, ladders, cranes,
etc.) are required?
11.5) Is there enough room/space for aerial devices and the ground condition
permit them to be fix/move.
11.6) Approach roads condition.
11.7) Other information of job site which you think necessary for execution of
the job.

13
12) Conduct a tailboard conference or meeting with the crew members so that
each member of the crew may know and understand his job and responsibility.

14
3.1 DESCRIPTION OF THE STEPS INVOLVED IN JOB PLANNING

1) Follow work program.

Each grids maintenance crew must have an approved work program involving
each equipment to be maintained by the crew in his work jurisdiction. See your
work program for the job to do.

2) Arrange maintenance procedures.

Each grid maintenance crew is supposed to have an approved package of
maintenance procedures regarding every type of maintenance work to be done, for
example regular maintenance, minor overhauling and major overhauling
procedures. Such a set of maintenance procedures should also be available at
central places in GSO organization. Check your package of such procedures and
make sure that you have procedure to do the job, otherwise arrange to get the same.

3) Arrange equipment manual and drawings.

Manufacturer’s manual of each type of equipment and a set of drawings (schematic
control diagram, A.C. and D.C schematic diagrams and wiring diagrams of each
equipment and grid station in the, jurisdiction of a grid maintenance crew) must be
available with the crew or at central places in GSO organization where they can be
easily available to the crew. Check your package and make sure that you have the
manual and drawings for the job to do, otherwise arrange to get the same.

4) Arrange previous maintenance record.

Each grid maintenance crew must be available with the previous maintenance
record of each equipment involved in their maintenance programme. This record is
actually the history of the equipment from where one can see the nature of
maintenance work done, such as type of faults, how they were rectified or any
fault/discrepancy still exists, test results etc. Get the previous maintenance record if
available. Also look at the last station inspection report to determine if there was a
problem reported. In future you will open a file on the concerned maintenance
record. These maintenance record files should be available in the control room at
each grid station in the custody of shift incharge, but not in the custody of grid
station incharge.

5) Arrange for the spare parts required.

Enough quantity of spares (such as equipment component parts, insulating oil, SF6
gas etc.) needed in regular maintenance, minor and major overhauling of the grid
equipment must always be available in stock of local/C-type/A-type stores or
warehouses of GSO organization. You will pay special attention regarding
availability of spares and submit demands to the higher well in time so that work
program may not suffer due to non-availability of spares. Get the spares required.

15
6) Arrange for T&P and test equipment needed.
Each grid maintenance crew is supposed to have a complete package of routine
used T&P and basic test equipment (Refer standard T&P list attached), otherwise
arrange to have the same. The type and quantity of T&P is determined by breaking
the job into a number of tasks and the T & P required for each task. Each crew may
not have all the test instruments and special tools due to being costly, so one or two
sets of these test equipment and special tools can be arranged at circle level and be
used by all the crews in that circle with mutual co-ordination. A guideline for this
mutual co-ordination is that work programs for crews in a circle should be prepared
in such a way that their work activities timings not overlap each other. You will get
the test equipment and special tools required for the job well before.

7) Estimate and arrange to meet the expenditures involved.

Following the NTDC financial rules and procedures, the crew in-charge should
submit his budget demands and get the required budget allocated for the financial
year. The crew may needs budget for overtime work payments, repair of vehicles,
purchase of cleaning and lubricating hard wares, medical bills, other petty purchase
and repairs etc. You will estimate and get the money required to meet the
expenditures with the job well before.

8) Estimate number of man-hours and the length of time required to complete the
job.
Keeping in view the nature of job to be done you will estimate the men required for
the job and for how much hours they will need to complete the job. This is done by
breaking the job into a number of tasks. Hence, you will estimate the total time
required for the job and the same will be the equipment shut down time if shut
down is required.

9) Arrange to get co-ordination of the other work groups (P&I, T/L, etc.) if needed.
To minimize the shut down on an equipment, inform other work groups (P&I, T/L
etc.) if they have to do some job on the same equipment. For example, P&I staff
can test the protection of a transformer when you have arranged its outage for
minor/major maintenance. Another example, that you are going to perform annual
maintenance on station battery ask P&I staff to verify and adjust settings of battery
charger.

10) Arrange shut down of the equipment to be worked on if needed. (refer to PTW
procedure).
If shut down of the equipment to be worked on is required, you have calculated the
duration of shut down (refer step-8), apply to the NPCC/RCC for shut down 72-
hours before the shutdown start time.

11) Inspect job site to look for:

16
11.1) Hazards: Hazard/accident is a result of unwanted energy flow. Look for the
energy forms involved in the work, such as body mechanics, chemical energy,
electrical energy, heat energy, light energy, mechanical energy, noise, pressurized
fluids (gases and liquids) etc. Look for the hazards due to fall, travel and contact.

11.2) Is there any chance of back feeding. What equipment are to be de-energized
to get safe working clearances?

11.3) Isolation points and grounding facilities.

11.4) What types of aerial devices (scaffold, bucket truck, ladders, etc.) and crane
are required?

11.5) Is there enough room/space .for aerial devices and ground condition permits
to be use/fixe/move them?

11.6) Condition of the approach roads be kept in mind.

11.7) Other information about job site, which you think necessary for execution of
the job.

12) Conduct a tailboard conference. You being in-charge of the crew will conduct a
conference/meeting with the crew members the day before commencing the work.
For emergency jobs it is also necessary to conduct a tailboard conference before
commencing the work for the following purposes:

12.1) To tell them what is the job to do,

12.2) To discuss the hazards identified at the site,

12.3) To assign the job/responsibility to each member,

12.4) To decide any changes to work methods,

12.5) To finalize the work plan,

12.6) To ensure each person knows what to do,

12.7) To develop a safety program for the job to be done. Some of the key points
for a safety program are;

12.7.1) Recognize the five basic safety principles as given below:

17
- Identify the hazards

- Eliminate the hazards wherever practical

- Control the hazards, when they cannot be eliminated

- Minimize the severity of injuries when a hazard is out of control

- Minimize severity of an injury after it has occurred

12.7.2) Consider safe limits of approach,

12.7.3) Use barriers and warning signs,

12.7.4) Use fall arrest and travel restrict systems.

4. JOB SAFETY AWARENESS AND SAFETY CODE

You will get safety awareness and follow the prescribed safety rules and
guidelines while on work for your own safety, of fellow workers and of the
company’s property. It is the responsibility of the man-in-charge and of each
crew member to constantly be on the lookout for safety hazards and to take
definite steps to eliminate or control all identified hazards.

Prior to undertaking any of the maintenance procedures, proper work

protection shall be established as necessary in accordance with the PTW and
the Company’s Safety Code. All work activities shall comply with applicable

18
safety rules and regulations. In addition to the above, a safety hazard
identification exercise shall be undertaken.

In a work place hazards are always expected to the workers and/or the
equipment. The unsafe acts and unsafe conditions increase the chances of
accidents whether fatal or non-fatal. Flow of unwanted energy also presents
accidents. Safety can be achieved only through intelligence, cooperation and an
understanding of and adherence to safety measures.

4.1 BASIC SAFETY GUIDE LINES

Personal safety is a primary feature of our daily work, whether at home or office or
field so all the employees of the company, mainly the un-trained and having multi-
nature jobs, must become familiar with these basic safety guide lines.

General Principles: Accident prevention can be accomplished only through

possessing and applying safety know-how and wholehearted cooperation of all
members of the organization. Learn and understand the following five basic
principles in job safety to deal with the hazards:

a) IDENTIFY the Hazards.

b) ELIMINATE the hazards wherever practical.
c) CONTROL the hazards when they cannot be eliminated.
d) PROTECT against injuries in case a hazard gets out of control.
e) MINIMIZE the severity of an injury, if an accident occurs.

- Neither management and supervision, nor the Safety Code can prevent accident
without the help of each employee.

- Unsafe workers are a danger to themselves, their fellow workers, the public
property and the equipment with which they work. Due care and attention to all
safety rules and devices is essential not only to prevent injury to the workers but
also to protect equipment.

- Capable and mentally alert employees will avoid accidents by learning all they
can about their work, using proper safeguards and protective equipment and
avoiding shortcuts and make shift work methods.

- Good operation is safe operation. This is true for both employees and equipment.
A job done safely is job done efficiently.

Accidents do not “just happen”. Accidents are the natural result of unsafe condition
or unsafe acts, usually a combination of both. Machinery and equipment generally
are manufactured to perform safely within limits of design. In fact, statistics show

19
that more than 90% of accidents are due to the human element, such as failure to
use safety devices and observe safety rules and procedures.

UNSAFE CONDITIONS: Some examples of unsafe conditions which may cause

accidents are:

Improper Guarding such as unshielded moving parts of machine, in-barricaded

floor openings and excavation, unenclosed high voltage equipment, lack of
protective equipment and insufficient warning signs etc.

Defective Material or equipment such as mushroomed-head chisels, split handles,

deteriorated poles, poorly manufactured or weak equipment.

Hazardous Arrangements such as those due to poor housekeeping at work

locations, unsafe planning or inadequate working space.

Insufficient Light unsuitable location producing glare or objectionable shadows.

Improper Ventilation such as insufficient change of air or presence of harmful

vapor, dust or gas.

Unsafe Clothing that fits loosely and can become entangled in wires and
machinery, and failure to use goggles, proper shoes and insulated gloves or sleeves.

Unsafe Design and Construction due to deviations from standard design and
specifications and poor workmanship.

UNSAFE ACTS: Some examples of unsafe acts which may cause accidents are:

Operating Without Authority or Warning such as closing switches without

authority, operating hoists and trucks without warning, failure to place warning
signs or signal man where needed, failure to block equipment against unexpected
movement, failure to observe work clearance procedures.

Operating or Working at Unsafe Speed such as driving too fast, throwing

material or tools to another worker, jumping from vehicles or platforms or running.

Making Safety Devices Inoperative such as removing guards from machines,

using oversize fuses, blocking safety valves, bypassing interlocks and isolating fire
protection etc.

Use of Unsafe Equipment or Improper Use of Equipment such as using dull

cutting tools, mushroom-head chisels, pipe extension on wrenches not designed for

20
them, or the wrong tool for the job, or using hands instead of hand tools.

Unsafe Loading such as overloading cranes and winches, carrying too heavy load.

Placing or Leaving Objects where they are likely to fall.

Mixing Improper Packing or combining chemicals to form a dangerous mixture.

Taking Unsafe Position or Posture such as working on live conductors from

above instead of below, walking under suspended loads or too close to openings,
lifting while in awkward position, entering areas where there are dangerous gases
or fumes, passing on curves of hills, riding on running boards or other unsafe
places on vehicles.

Working on Equipment without Taking Proper Precautions such as installing

and removing temporary earth, cleaning, oiling or adjusting moving machinery,
and working on or near live electrical equipment.

Distracting, Teasing or Startling such as practical joking, horseplay, quarrelling

or annoying.

Failure to Use Safe Clothing or Protective Equipment such as failure to use

insulated gloves, hardhat or goggles or other personal protective equipment (PPE).

5. MAINTENANCE SCHEDULE AND CHECKS; GRID STATION

EQUIPMENT

Preventive maintenance is a cycle of planned inspections, work activities and tests

to be implemented to get and ensure safe and reliable performance of equipment
and infrastructure components of the grid system. The maintenance cycle or
frequency of implementation is given in terms of time-periods, which can be
modified due to environmental conditions and constraints of the man-hours and
quantity of the equipment under the jurisdiction of the work crew.

The check sheets given hereunder describe only the maintenance schedules and
checks/tests in terms of what to do and when to do. For the aspect of how to do,
one should consult relevant manufacturer’s instruction manual, TSG training
course books and/or TSG technical experts. In addition to the inspection and
maintenance activities given in this SOP, manufacturer’s recommended
instructions are also applicable.

The symbols used for time-periods for inspection and maintenance/frequency of

implementation are as under:

21
D stands for daily,
W stands for weekly,
M stands for monthly,
Y stands for yearly.

1. MAINTENANCE OF POWER TRANSFORMERS

22
 250MVA, 220/132KV Auto Transformer at 220kV G/S NKLP Lahore

SOP CHECK SHEET: MAINTENANCE SCHEDULE AND

CHECKS/TESTS OF POWER TRANSFORMERS
Description of Inspection Specified Time Period Remarks/Criteria/Standard/Safety
and Maintenance Work D/W M3-6 Y1 Y5- Precautions
10
1. Visual inspection (A Yes - - - Wear PPE and carry basic tools,

23
walk around visual multi-meter, clip-on-ammeter, etc.
inspection from ground Make entries of the observations in
level and keeping in view check sheets/note book.
the safe limits of approach
to live and moving parts to
check apparent condition,
abnormal noise, rust on
body of the equipment and
component parts, etc.)
2. Oil level: Conservator Yes - - - Should be OK as per indicator. The
Tank Main indicator should be kept clean and
visible. Should be no oil leakages
3. Oil level: Conservator Yes - - - Should be OK as per indicator. The
Tank OLTC indicator should be kept clean and
visible. Should be no oil leakages
4. Oil level: Bushings Yes Should be OK as per indicator. The
indicator should be kept clean and
visible. Should be no oil leakages
5. De-railing locking Yes - - - Should be intact as per design
devices
6.Cooling System (AF): Yes - - - Should be as per transformer
Fans construction design and operative.
Check for proper speed, correct
direction and noisy bearings.
7. Cooling System(OF): Yes - - - Should be as per transformer
Oil Circulation Pumps construction design and operative.
Check for correct direction and
noisy bearings.
8. Oil Temperature Gauges Yes - - - Should be healthy and accurate
9. Oil Temperature Yes - - - Should be OK at local/remote
Indicators
10. Winding Temperature Yes - - - Should be healthy and accurate
Gauges
11. Winding Temperature Yes - - - Should be OK at local/remote
Indicators
12. Ground Connections of Yes - - - Measure neutral current with clip-
Neutral Terminal on-ammeter to ensure healthy
connection between terminal and the
earth mesh. Transformer neutral is
grounded at two points i.e. with
earth mesh and with separate earth
electrode.
13. Ground Connections of Yes - - - Should be proper and tight. Measure
Body Tank leakage current with clip-on-
ammeter to ensure healthy
connection between the body tank
and earth mesh. Transformer body
tank has two grounding points.
14. Ground Connections of Yes - - - Measure neutral current with clip-
Tertiary Winding Terminal on-ammeter to ensure healthy

24
as applicable (see note at connection between the terminal and
the end) earth mesh.

15. Silica-gel Breather of Yes - - - Bubbling in the oil indicates healthy

Main Conservator Tank breathing. The colour of silica-gel
should be BLUE and oil in glass pot
clean. If 1/3 volume of the silica-gel
has changed colour into PINK then
recondition or replace the whole
silica-gel
16. Silica-gel Breather of Yes - - - Bubbling in the oil indicates healthy
OLTC Conservator Tank breathing. The colour of silica-gel
should be BLUE colour and oil in
glass pot clean. If 1/3 volume of the
silica-gel has changed colour into
PINK then recondition or replace the
whole silica-gel
17. Oil Leakages all around Yes - - - Should be no oil leakages
the transformer
18. Bushing Condition Yes - - - Should be neat and clean, no
(HV, LV, Neutral, Tertiary, damages and no oil leaks
etc.)
19. Bushing Terminal Yes* - Yes - Dismantle connections, clean
Connections (HV, LV properly, apply corrosion inhibitor
,Neutral, Tertiary, etc.) and fix/tight with recommended
torque. Should be no hotspot/s (*
check during night
patrolling/thermovision survey).
While handling bushing terminal
connections, take care of oil sealing
system, arcing horns (if provided),
the spacing between electrodes
should be as per recommendations
and/or in accordance with 1cm per
kV of the rated phase-to-ground
voltage. In 500/220kV transformers,
tertiary winding terminals are
enclosed in separate cubicle, give
special attention to water proofing
and vermin proofing of the cubicle.
20. Radiator Tubes Fixture Yes - - - Should be secured with proper
clamping/supports
21.Radiator Tubes Valves - - Yes - The valves should always be kept
opened, operative and no oil leaks
(the temperature of radiator tubes
should be observed by touching the
tubes and feeling the degree of
hotness by comparison with each
other tube
22. Pressure Relief Devices - - Yes - Should be intact, no damages, and

25
(PRD)/Auto Reset Relief healthy micro switch and wiring
Vent terminal connections
23. Buchholz Relay - - Yes - Should be operative, no damages,
arrow mark points toward
conservator tank, 0.5o to 1o
ascending level towards conservator
tank, gas sampling valve operative
(in some models a separate device
for gas collection is provided near
ground level of the transformer tank)
, no oil leaks, cover packing healthy,
neat & clean, proper glands at
wiring cable entrance and moisture
proofing, wiring terminals tight,
velocity setting (65/100/150 cm per
second, factory setting is normally at
100 cm/s), etc.
Control Cubicle
24. Doors, Door locks, Yes - - - Should be OK and no defect/damage
Door packing, Door stops,
Light, Cleaning, Ground
connections, Proper glands
at wiring cable entrance,
Wiring cable numbering,
Vermin proofing, etc.
25. Space heaters & - Yes - - Should be intact and operative
Thermostat setting
26. Wiring and Terminal - - Yes - Should be tight and secured
Blocks
27. Control Switches and - Yes - - Should be as per design, healthy and
Accessories secured
On Load Tap Changers (OLTC)
28. Motor drive unit Yes - - - Should be OK and no defect/damage
cubicle: Doors, Door locks,
Door stops, Door packing,
Light, Cleaning, Proper
glands at wiring cable
entrance, Wiring cable
numbering, Vermin
proofing, Ground
connections, etc.
29. Tap Position Indication Yes - - - Should be OK and no defect
(Local/Remote)
30. Motor drive unit - - Yes - Should be tight and secured
cubicle: Wiring and
Terminal Blocks
31. Motor drive unit Yes - - - Should be intact and operative
cubicle: Space heaters &
Thermostat setting
32. Motor drive unit Yes - - - Should be OK and no defect/damage

26
cubicle: Controls and
Accessories
33. Motor drive unit Yes - - - Should be healthy functioning.
cubicle: Operation Counter Record reading for over hauling
Reading reference
34. Motor drive unit - - Yes - Should be healthy functioning
cubicle: Step-by-Step
Function
35. Motor drive unit - - Yes - Should be healthy functioning
cubicle: Extreme Electrical
Limits Stop Function (on
both raise/lower ends)
36.Motor drive unit - - Yes - Should be healthy functioning
cubicle: Extreme
Mechanical Limits Stop
Function (on both
raise/lower ends)
39.Motor drive unit - - Yes - Should be healthy functioning
cubicle: Safety Switch
Function
40. Motor drive unit - - Yes - Should be healthy functioning
cubicle: Emergency Stop
Function
41. Motor drive unit - - Yes - Should be OK as per indicator.
cubicle: Gearbox Replace oil as applicable and with
Lubrication Oil Level and recommended type of oil. The
Condition indicator should be kept clean and
visible
42. Motor drive unit - - Yes - Should be OK as per original design
cubicle: Motor Drive Belt
Tension and Condition
43. Bevel Gearboxes - - - Yes Apply grease. Ensure for intact
Greasing water proofing of the box
44. Auto Voltage - - Yes - Verify settings
Regulator (AVR) (if
applicable)
45. Inspection and - - - Yes As per specifications (overhauling of
Overhauling of OILTAP OLTC is due after 4-5 years or after
OLTC. specified number of operations,
Inspection and whichever comes first).
Overhauling of OLTC
Diverter Switches
(cleaning, checking
contacts, measurement of
transition resistors value,
replacements as applicable,
etc.)
46. Simultaneous - - - Yes All the Diverter Switches must
Operation of Diverter operate within half-cycle of hand
Switches if more than one cranking

27
units are provided
47. Rotation Lack - - - Yes Should be equal rotations for Raise
Balancing and Lower operation after switching
action in the diverter switch
48. Diverter Switch - - Yes - Should be operative, no damages,
Compartment Protective arrow mark points toward
Relay (RS2001 or other conservator tank, 0.5o to 1o
models) ascending level towards conservator
tank, no oil leaks, cover packing
healthy, proper glands at wiring
cable entrance and moisture
proofing, neat & clean, wiring
terminals tight, etc.
49. OLTC Test Operations - - Yes - Should be OK from Local/Remote
(Raise and Lower) and/or Auto
50. Inspection and - - - Yes VACUTAP OLTC Make: MR and
Overhauling of VACUTAP Type; VV has been provided in
OLTC. 132/11kV Power Transformers and
Inspection and type VR in 220/132kV Auto
Overhauling of OLTC Transformers.
Diverter Switches Inspection/overhauling has been
(cleaning, checking of recommended after 300,000
vacuum interrupters, operation as per technical
measurement of transition specifications.
resistors value,
replacements as applicable,
etc.)
51. Simultaneous - - - Yes All the Diverter Switches must
Operation of Diverter operate within half-cycle of hand
Switches if more than one cranking
units are provided
52. Rotation Lack - - - Yes Should be equal rotations for Raise
Balancing and Lower operation
53. Diverter Switch - - Yes - Should be operative, no damages,
Compartment Protective arrow mark points toward
Relay (RS2001 or other conservator tank, 0.5o to 1o
models) ascending level towards conservator
tank, no oil leaks, cover packing
healthy, proper glands at wiring
cable entrance and moisture
proofing, neat & clean, wiring
terminals tight, etc.
54. OLTC Test Operations - - Yes - Should be OK from Local, Remote
(Raise and Lower) and/or Auto
OFF LOAD TAP CHANGER (if applicable)
55. Off Load Tap Changer - - Yes - Should be OK from Local
Test Operation
Tests
56. DES test of Oil of main - - Yes - DES value should be >30kV, 40kV,
tank and OLTC 50kV at 2.5 mm gap for 66kV,

28
compartments 132kV, 220kV/ 500kV respectively
57. Chemical Analysis of - - - Yes Should be as per test laboratory
Oil specifications
58. Tangent Delta (Tan δ) - - - Yes Should be as per test laboratory
test of Oil specifications
59. Dissolved Gases - - Yes - Should be as per test laboratory
Analysis (DGA) of oil specifications
60. Insulation Resistance - - Yes - Should be as per commissioning test
test (Megger test) of results and/or specifications after
Windings correction of test results at 20 °C
61. Insulation Resistance - - Yes - Should be as per commissioning test
test (Megger test) of Core results and/or specifications after
and/or Clamping correction of test results at 20 °C
62. Insulation Resistance - - Yes - Should be as per commissioning test
test of tertiary bus bar of results and/or specifications after
single-phase bank correction of test results at 20 °C
connection transformers
63. Capacitance and - - Yes - Should be as per commissioning test
Dissipation Factor test results and/or specifications after
(C&DF test) of windings correction of %DF test results at 20
and bushings °C
64. Transformer Turn - - Yes - Should be as per commissioning test
Ratio test (TTR test) results and/or specification
(tolerance: ± 0.5% between
calculated and measured values)
65. Short circuit test - - Yes - Should be as per commissioning test
(special test) results and balanced current values.
In the short circuited “Y” winding,
check for abnormal current value in
neutral lead during OLTC operation
which indicates damage to transition
resistors of OLTC. The applied 3-
phase voltage should also be
balanced
66. Open circuit test - - Yes - Should be as per commissioning test
(special test) results and balanced voltage ratio.
This test is also a substitute of TTR
test. The applied 3-phase voltage
should also be balanced
67. Winding Resistance - - Yes - Should be as per commissioning test
test results and/or specifications after
correction of test results at 75 °C(*)
68. Sweep Frequency - - - Yes Should be as per commissioning test
Response Analysis (SFRA) results and /or factory test results
69. Buchholz Relay - - Yes - Should be OK and intact
functional tests; Alarm and
Trip, Indications and
Alarm
70. OLTC Protective Relay - - Yes - Should be OK and intact

29
functional tests; Trip and
Reset, Indications (local
mechanical and remote)
and Alarm
71. Oil temperature; Alarm - - Yes - Should be OK and intact
and Trip test, Indications
and Alarm
72. Winding temperature; - - Yes - Should be OK and intact
Alarm and Trip test,
Indications and Alarm
73. Pressure Relief Device - - Yes - Should be OK and intact
(PRD); Trip test,
Indications (local,
mechanical and remote)
and Alarm

Note. TERTIARY WINDING (Transformers with more than two windings)

When a power transformer or auto transformer is “Y” connected both on high voltage and low
voltage, triple frequency component (3rd harmonic) of the magnetizing current is suppressed and
a corresponding voltage is induced in both windings. This voltage is usually negligible in three-
phase core-type transformers, but in single-phase units it can be dangerous. To allow triple
frequency current to flow and thus eliminate this over-voltage, a third or tertiary winding is
usually provided. This winding must be connected in delta, whether or not it is to be used as a
source of power.

In the event of failure of one phase of three-phase core-type transformer, it cannot be operated
with two phases in open-delta, unless the entire damaged phase is removed from the core, or
unless every damaged turn is open-circuited and the series connection between the other coils of
the damaged phase broken in three or four places.

Three-phase transformers are usually arranged for simultaneous loading on all three windings. In
many transformers, it is permissible to take full-load current from both the secondary and tertiary
windings, provided the power-factor between these loads is such that only full-load current is
drawn from the primary. There are other cases where the transformer has not been designed to
dissipate the losses due to full-load current in all three windings without over-heating. These
windings should be loaded in accordance with nameplate specifications.

Protection of floating windings

Windings which are not connected to a transmission system or load may be termed “floating”
windings. Under unfavourable conditions, such as lightning, and arcing grounds, these windings
may assume abnormally high electrostatic charges. It is desirable to guard against such charges
by grounding the neutral if “Y” connected, or one corner of the delta, if delta connected.
If it is not possible to do this, provide suitable lightning arresters, or connect the circuit (or at
least one lead) to a load or network having large capacitance to ground.
REFERENCE: Instructional manual of Canadian General Electric (CGE) Guelph, Ontario
Canada make 450 MVA (3x150), 500/220/11kV auto transformers, year of manufacturing 1976
at 500 kV G/S Gatti, Faisalabad).

Note. CORRECTION OF INSULATION RESISTANCE TEST RESULTS AT

30
STANDARD TEMP ERATURE 20 °C
Because most of the insulation materials have a negative temperature co-efficient i.e. , the
resistance decreases with increase in temperature, so the IR value should be corrected to a
standard temperature of 20 °C.
Roughly IR value decreases to ½ of its value for every 10 °C rise in the temperature
above 20 °C. So for correction at 20 °C, for every 10 °C rise in the temperature above 20 °C,
increase the measured value to 2 times. Formula for accurate temperature correction calculations;
IR 20 = IRt x 2^(t – 20) /10
where IR 20 is the corrected value at 20°C, t is the temperature of insulation mass and IRt
is the measured insulation resistance value at temperature t °C.
IR value is usually in mega ohms (M Ω).

Note. CORRECTION OF WINDING RESISTANCE TEST RESULTS AT STANDARD

TEMPERATURE 75 °C
The measured of winding resistance value should be corrected to a standard temperature of 75
°C.
R 75 = Rt (235 + 75) / (235 + t) Ω
where R 75 is the corrected value at 75°C, t is the winding temperature and Rt is the measured
winding resistance value at temperature t °C.

2. MAINTENANCE OF CIRCUIT BREAKERS

31
 220kV SF6 Gas Circuit Breaker make; SIEMENS at Mangla Power House

SOP CHECK SHEET: MAINTENANCE SCHEDULE AND

CHECKS/TESTS OF HV CIRCUIT BREAKERS
Description of Inspection and Specified Time Period Remarks/Criteria/Standard/
Maintenance Work D/W M3-6 Y1 Y5/10 Safety Precautions

32
1. Visual inspection (A walk Yes - - - Wear PPE and carry basic
around visual inspection from tools, multi-meter, clip-on-
ground level and keeping in ammeter, etc. Make entries of
view the safe limits of the observations in check
approach to live and moving sheets/note book.
parts to check apparent
condition, abnormal noise, rust
on body of the equipment and
component parts, position of
opening and closing indicators,
etc.)
2. SF6 Gas Pressure (GCB) Yes - - - Should be OK as per rated
pressure/indicator and
corrected at temperature 20
°C (*). The indicator should
be kept clean and visible.
Should be no gas leakages
*(+0.025 bar for every 1°C)
3. Oil Level (OCB) Yes - - - Should be OK as per
indicator. The indicator
should be kept clean and
visible. Should be no oil
leakages
4. Air Pressure (ABCB) Yes Should be OK as per rated
pressure/indicator. The
indicator should be kept clean
and visible. Should be no oil
leakages
5. Steel Structure Ground Yes - - - Should be OK as per design
Connections
6. HV Terminal Connections - - Yes - Dismantle connections, clean
properly, apply corrosion
inhibitor and fix/tight with
recommended torque. Should
be no hotspot/s (check during
night patrolling/thermovision
survey)
7. Porcelain Bushing Condition Yes - - - Should be clean and no
damage
8. Supporting Structure - Yes - - Should be OK as per design,
Nut/Bolts/Level and tight and secured
Control Cubicle
9. Cubicle Doors, Door locks, Yes - - - Should be OK and no
Door packing, Door stops, defect/damage
Light, Cleaning, Proper glands
at wiring cable entrance,
Wiring cable numbering,
Vermin proofing, Ground
connections, etc.
10. Control switches, Key Yes - - - Should be OK and no

33
switches, Indications, defect/damage
Accessories, etc.
11. Space heaters & Yes - - - Should be intact and operative
Thermostat setting
12. Wiring and Terminal - - Yes - Should be tight and secured
Blocks
13. Operation Counter Yes - - - Should be intact and operative
Motor Spring Operating Mechanism
14. Cubicle Doors, Door locks, Yes - - - Should be OK and no
Door packing, Door stops, defect/damage
Light, Cleaning, Proper glands
at wiring cable entrance,
Wiring cable numbering,
Vermin proofing, Ground
connections, etc.
15. Control switches, Key Yes - - - Should be OK and no
switches, Indications, defect/damage
Accessories, etc.
16. Space heaters & Yes - - - Should be intact and operative
Thermostat setting
17. Wiring and Terminal - - Yes - Should be tight and secured
Blocks
18. Operation Counter Yes - - - Should be intact and operative
19. Cleaning Yes - - - Should be OK neat and clean
20. Closing Spring Motor - - Yes - Should be OK as
Charging Time recommended (usually <
15sec)
21. Lubrication of - - Yes - Should be OK as per
moving/sliding/rolling parts recommendations
22. Closing Dash Pot Oil Level - - Yes - Should be OK as per design
23. Opening Dash Pot Oil - - Yes - Should be OK as per design
Level
24. Manual Charging of - - Yes - Should be OK as per design
Closing Spring
25. Supporting Structure - Yes - - Should be OK as per design,
Nut/Bolts/Level tight and secured
26. CB Close/Open or ON/OFF Should be in accordance with
Indication the actual position of CB and
(electrical/mechanical OK as per design
indicators)
Hydraulic Oil Pressure Operating Mechanism
27. Cubicle Doors, Door locks, Yes - - - Should be OK and no
Door packing, Door stops, defect/damage
Light, Cleaning, proper glands
at wiring cable entrance,
Wiring cable numbering,
Vermin proofing, Ground
connections, etc.
28. Control switches, Key Yes - - - Should be OK and no

34
switches, Indications, defect/damage
Accessories, etc.
29. Space heaters & Yes - - - Should be intact and operative
Thermostat setting
30. Wiring and Terminal - - Yes - Should be tight and secured
Blocks
31. Operation Counter Yes - - - Should be intact and operative
32. Hydraulic Oil Level Yes - - - Should be OK as per design
33. Hydraulic Oil Replacement - - - Yes Should be replaced as per
recommendations
34. Hydraulic Oil Pressure Yes - - - Should be OK as per design
35. Hydraulic Oil Leakages Yes - - - Should be no leakages
36. N2 Gas Pressure - - Yes - Should be OK as per design
37. Hydraulic Oil: Low - - Yes - Should be OK as per design
Pressure Alarm and Lockout and remote indications
Check
38. Hydraulic Oil Filter Check - - Yes - Should be OK as per design,
clean or replace the filter as
per recommendations
39. Hydraulic Oil Pressure - - Yes - Should be OK as per
Safety Valve Function Check recommendations
40. Hydraulic Oil Pump: Cut - - Yes - Should be OK as per
IN/OUT Pressure Value Check recommendations
41. Hydraulic Oil Pump and Yes - - - Should be OK as per design,
Accessories Mounting Tight and secure
Structure Nut/Bolts/Level
Pneumatic Operating Mechanism
42. Cubicle Doors, Door locks, Yes - - - Should be OK and no
Door packing, Door stops, defect/damage
Light, Cleaning, proper glands
at wiring cable entrance,
Wiring cable numbering,
Vermin proofing, Ground
connection, etc.
43. Control switches, Key Yes - - - Should be OK and no
switches, Indications, defect/damage
Accessories, etc.
44. Space heaters & Yes - - - Should be intact and operative
Thermostat
45. Wiring and Terminal - Yes - - Should be tight and secured
Blocks
46. Operation Counter Yes - - - Should be intact and operative
47. Rated Air Pressure Yes - - - Should be OK as per design
48. Rated Air Pressure: Low - - Yes - Should be OK as per design
Pressure Alarm and Lockout and remote indications
Check
49. Air Compressor: Air Intake - Yes - - Should be OK as per design,
Filter Check clean or replace filter as per
recommendations

35
50. Air Compressor: - Yes - - Should be OK as per design,
Lubrication Oil Level and replace oil as recommended
Condition Check
51. Air Compressor: Operation Yes - - - Should be intact and operative
Hours Counter Check
52. Air Pressure: Safety Valve - - Yes Should be OK as per
Function Check recommendations
53. Air Compressor and - Yes - - Should be OK as per design,
Accessories Mounting and tight and secured
Structure Nut/Bolts/Level
Tests
54. Test Operation: ON/OFF - - Yes - Should be intact and operative
Local/Remote/Auto along with remote indications
55. CB Position Mechanical Yes - - - Should be correct as per
Indication (ON/OFF) actual position
56. Oil DES Test (OCB) - - Yes - DES value should be >40 KV
at 2.5 mm gap, Replace oil
after 10 tripping
57. SF6 Gas Purity Test (GCB) - - Yes - Purity should be > 97 %
58. SF6 Dew Point/Moisture - - Yes - Dew point should be >-15°C
Contents Test (GCB) or Moisture contents should
be < 50 PPm
59. Contact Resistance Test - - Yes - Should be OK as
recommended
60. Close/Open Time Test - - Yes - Should be OK as
recommended. The
permissible differences
between timings of 3-poles
and between timings of
breaks within 1-pole are:
Closing time: 5ms (1/4 cycle)
Opening time: 3.33ms (1/6
cycle)
Within breaks of 1-pole:
2.5ms (1/8 cycle)
61. Anti-Pumping Feature - - Yes - Should be OK and intact
Check
62. Pole Discrepancy Control - - Yes - Should be OK and intact,
Feature Check remote indication
(applicable in single-pole
operated CBs)
63. Minimum Voltage - - Yes - The CB should open at 50-
Close/Open Test 75% voltage of rated value
and close at 80% voltage of
rated value
64. SF6 Gas: Low Pressure - - Yes - Should be OK as per design
Alarm and Lockout Check and remote indications

36
3. MAINTENANCE OF ISOLATORS/DISCONNECT SWITCHES

37
 220kV Isolator/Disconnect switch at 500 kV G/S NTDC Sheikhupura

SOP CHECK SHEET: MAINTENANCE SCHEDULE AND

CHECKS/TESTS OF ISOLATORS/DISCONNECT SWITCHES (BUS BAR
AND LINE)
Description of Inspection and Specified Time Period Remarks/Criteria/Standard/
Maintenance Work D/W M3-6 Y1 Y5/10 Safety Precautions
1. Visual inspection (A walk Yes - - - Wear PPE and carry basic
around visual inspection from tools, multi-meter, clip-on-

38
ground level and keeping in ammeter, etc. Make entries of
view the safe limits of the observations in check
approach to live and moving sheets/note book.
parts to check apparent
condition, abnormal noise, rust
on body of the equipment and
component parts, position of
opening and closing indicators,
etc.)
Isolator
2. Contact Alignment Yes - - - Should be OK either fully
(Close/Open) Closed or Opened
3. Contact Grip/Pressure (Close Yes - - - Should be OK as per contact
Position) fingers design
4.Mechanical Stops Yes - - - Should be OK as per design
5. Steel Structure Ground Yes - - - Should be OK as per design
Connections
6. Inter Phases Mechanical Yes - - - Should be intact and no
Linkages damages
7. HV terminal/connector - - Yes - Should be OK as per design
bearing condition & lubrication
8. HV Terminal Connections Yes - - - Should be OK as per design
and no hotspot/s (check
during night patrolling /
thermovision survey)
9. Porcelain Insulator Yes - - - Should be Clean and no
Condition damage
10. Porcelain Insulator base - - Yes - Should be OK as per design
bearing condition & lubrication
10. Supporting Structure Yes - - - Should be OK as per design
Nut/Bolts/Level and tight and secured
Earth Switch (For Line Isolator)
11. Earth Blade/Contact Yes - - - Should be OK either fully
Alignment (Close/Open) Closed or Opened
12. Contact Grip/Pressure Yes - - - Should be OK as per contact
(Close Position) fingers design
13. Mechanical Stops Yes - - - Should be OK as per design
14. Ground Connections Yes - - - Should be OK as per design
15. Inter Phases Mechanical Yes - - - Should be intact and no
Linkages damages
Control Cubicle
16. Cubicle Doors, Door locks, Yes - - - Should be OK and no
Door packing, Door stops, defect/damage
Light, Cleaning, proper glands
at wiring cable entrance,
Wiring cable numbering,
Vermin proofing, Ground
connections, etc.
17. Control switches, Key Yes - - - Should be OK and no

39
switches, Indications, defect/damage
Accessories, etc.
18. Space heaters & Yes - - - Should be intact and operative
Thermostat setting
19. Wiring and Terminal - - Yes - Should be tight and secured
Blocks
20. Operation Counter Yes - - - Should be intact and operative
Operating Mechanism of Isolator
21. Cubicle Doors, Door locks, Yes - - - Should be OK and no
Door packing, Door stops, defect/damage
Light, Cleaning, proper glands
at wiring cable entrance,
Wiring cable numbering,
Vermin proofing, Ground
connections, etc.
22. Control switches, Key Yes - - - Should be OK and no
switches, Indications, defect/damage
Accessories, etc.
23. Space heaters & Yes - - - Should be intact and operative
Thermostat setting
24. Wiring and Terminal - - Yes - Should be tight and secured
Blocks
25. Operation Counter Yes - - - Should be intact and operative
26. Cleaning Yes - - - Should be OK neat and clean
27. Lubrication of - - Yes - Should be OK as per
moving/sliding/rolling parts recommendations
28. Manual Operation: - - Yes - Should be intact and operative
Close/Open
29. Supporting Structure - Yes - - Should be OK as per design,
Nut/Bolts/Level tight and secured
30.Ground Potential Gradient Yes Should be OK as per design,
Control Mat Condition and tight and secured
Grounding
Operating Mechanism of Earth Switch
31. Cubicle Doors, Door locks, Yes - - - Should be OK and no
Door packing, Door stops, defect/damage
Light, Cleaning, proper glands
at wiring cable entrance,
Wiring cable numbering,
Vermin proofing, Ground
connections, etc.
32. Control switches, Key Yes - - - Should be OK and no
switches, Indications, defect/damage
Accessories, etc.
33. Space heaters & Yes - - - Should be intact and operative
Thermostat setting
34. Wiring and Terminal - - Yes - Should be tight and secured
Blocks
35. Operation Counter Yes - - - Should be intact and operative

40
35. Cleaning Yes - - - Should be OK neat and clean
36. Lubrication of - - Yes - Should be OK as per
moving/sliding/rolling parts recommendations
38. Manual Operation: - - Yes - Should be intact and operative
Close/Open
39. Supporting Structure - Yes - - Should be OK as per design,
Nut/Bolts/Level tight and secured
40.Ground Potential Gradient Yes Should be OK as per design,
Control Mat Condition and tight and secured
Grounding
Tests
41. Test Operation: ON/OFF - - Yes - Should be intact and operative
Local/Remote (Check Scheme along with remote semaphore
for Earth Switch Test indications
Operation)
42. Contact Resistance Test - - Yes - Should be OK as
recommended
43. Mechanical Inter Locking - - Yes - Should be OK as per design
44. Electrical Inter Locking - - Yes - Should be OK as per scheme
With CB
45. Inter Locking Between - - Yes - Should be OK as per scheme
Isolator and Earth Switch

41
4. MAINTENANE OF CURRENT TRANSFORMERS (CT)

220kV Current Transformer at 550kV G/S NTDC Sheikhupura

SOP CHECK SHEET: MAINTENANCE SCHEDULE AND

CHECKS/TESTS OF CURRENT TRANSFORMERS (CT)
Description of Specified Time Period Remarks/Criteria/Standard/Safety
inspection and D/W M3-6 Y1 Y5/10 Precautions

42
maintenance work
1. Visual inspection (A Yes - - - Wear PPE and carry basic tools,
walk around visual multi-meter, clip-on-ammeter, etc.
inspection from ground Make entries of the observations in
level and keeping in view check sheets/note book.
the safe limits of
approach to live and
moving parts to check
apparent condition,
abnormal noise, rust on
body of the equipment
and component parts,
etc.)
2. Oil Level Yes - - - Should be OK as per indicator. The
indicator should be kept clean and
visible. Should be no oil leakages
3. HV Terminal Yes - - - Should be OK as per design and no
Connections (P1&P2) hotspot/s (check during night
patrolling/thermovision survey)
4. Porcelain Bushing Yes - - - Should be clean and no damage
Condition
5. Supporting Structure - Yes - - Should be OK as per design, tight
Nut/Bolts/Level and secured
6. Ground Connections Yes - - - Should be OK as per design
7.Secondary Terminal Yes - - - Should be OK and no damage/no
Box: Cover, Cover locks, defect, water proofing & vermin
Cover packing, Cleaning, proofing intact
Proper glands at wiring
cable entrance, Wiring
cable numbering, Vermin
proofing, Ground
connections, etc.
8. Secondary Terminal - - Yes - Should be tight and secured
Connections
Tests
9. DES test of Oil (special - - - Yes DES value should be >30kV, 40kV,
test) 50kV at 2.5 mm gap for 66kV,
132kV, 220kV/ 500kV respectively
10. Chemical Analysis of - - - Yes Should be as per test laboratory
Oil (special test) specifications
11. Tangent Delta (Tan δ) - - - Yes Should be as per test laboratory
test of Oil (special test) specifications
12. Dissolved Gases - - - Yes Should be as per test laboratory
Analysis (DGA) of oil specification
(special test)
13. Insulation Resistance - - Yes - Should be as per commissioning test
test (Megger test) of results and/or specifications after
Windings correction of test results at 20 °C
14. Capacitance and - - Yes - Should be as per commissioning test

43
Dissipation Factor test results and/or specifications after
(C&DF test) of windings correction of %DF results at 20 °C
15. Magnetizing or - - - Yes Should be as per commissioning test
Exciting Current/Knee- results and /or specification
Point Voltage Test
(special test)
16. Current Ratio and - - - Yes As per selected primary/secondary
Accuracy Test (special current ratio and /or specifications.
test) Accuracy test results should be in
accordance with the relevant
Metering/ Protection core
specifications.
17. Nitrogen (N2) Gas - - - Yes Should be OK as per design
Pressure Check (if
applicable)
Marshaling Kiosk/Cubicle
18. Doors, Door locks, Yes - - - Should be OK and no defect/damage
Door packing, Door
stops, Light, Cleaning,
Proper glands at wiring
cable entrance, Wiring
cable numbering, Vermin
proofing, Ground
connections, etc.
19. Space heaters & Yes - - - Should be intact and operative
Thermostat setting
20. Wiring and Terminal - - Yes - Should be tight and secured
Blocks

5. MAINTENANCE OF POTENTIAL TRANSFORMERS (PT)

44
 132 kV Potential Transformers (Bus bar PT) at 220kV G/S NTDC NKLP
Lahore

SOP CHECK SHEET: MAINTENANCE SCHEDULE AND

CHECKS/TESTS OF POTENTIAL TRANSFORMERS (PT)
Description of Specified Time Period Remarks/Criteria/Standard/Safety
Inspection and D/W M3/M6 Y1 Y5/10 Precautions
Maintenance Work

45
1. Visual inspection (A Yes - - - Wear PPE and carry basic tools,
walk around visual multi-meter, clip-on-ammeter, etc.
inspection from ground Make entries of the observations in
level and keeping in check sheets/note book.
view the safe limits of
approach to live and
moving parts to check
apparent condition,
abnormal noise, rust on
body of the equipment
and component parts,
etc.)
2. Oil Level Yes - - - Should be OK as per indicator. The
indicator should be kept clean and
visible. Should be no oil leakages
3. HV Terminal Yes - - - Should be OK as per design and no
Connections (Line) hotspot/s (check during night
patrolling/thermovision survey)
4. Porcelain Bushing Yes - - - Should be clean and no damage
Condition
5. Supporting Structure - Yes - - Should be OK as per design, tight
Nut/Bolts/Level and secured
6. Ground Connections Yes - - - Should be OK as per design
7. Secondary Terminal Yes - - - Should be OK and no damage no
Box: Cover, Cover defect, water proofing & vermin
locks, Cover packing, proofing intact
Cleaning, Proper glands
at wiring cable entrance,
Wiring cable
numbering, Vermin
proofing, Ground
connections, etc.
8. Secondary Terminal - - Yes - Should be tight and secured
Connections
Tests
9. DES test of Oil - - - Yes DES value should be >30kV, 40kV,
(special test) 50kV at 2.5 mm gap for 66kV,
132kV, 220kV/ 500kV respectively
10. Chemical Analysis - - - Yes Should be as per test laboratory
of Oil (special test) specifications
11. Tangent Delta (Tan - - - Yes Should be as per test laboratory
δ) test of Oil (special specifications
test)
12. Dissolved Gases - - - Yes Should be as per test laboratory
Analysis (DGA) of Oil specification
(special test)
13. Insulation - - Yes - As per commissioning test results
Resistance test (Megger and/or specifications after correction
test) of Windings of test results at 20 °C

46
14. Voltage Ratio and - - - Yes Should be as per specifications
Accuracy Test (special
test)
Marshaling Kiosk/Cubicle
15. Doors, Door locks, Yes - - - Should be OK and no defect/damage
Door packing, Door
stops, Light, Cleaning,
Proper glands at wiring
cable entrance, Wiring
cable numbering,
Vermin proofing,
Ground connections, etc.
16. Space heaters & Yes - - - Should be intact and operative
Thermostat setting
17. Wiring and Terminal - - Yes - Should be tight and secured
Blocks

6. MAINTENANCE OF CAPACITOR VOLTAGE TRANDFORMERS

(CVT)

47
220KV Capacitor Voltage Transformer (Make: HAEFELY) at 220kv G/S
NTDC Summandri Road Faisalabad

48
SOP CHECK SHEET: MAINTENANCE SCHEDULE AND
CHECKS/TESTS OF CAPACITOR VOLTAGE TRANSFORMERS (CVT)
Description of Specified Time Period Remarks/Criteria/Standard/Safety
Inspection and D/W M3/M6 Y1 Y5/10 Precautions
Maintenance Work
1. Visual inspection (A Yes - - - Wear PPE and carry basic tools,
walk around visual multi-meter, clip-on-ammeter, etc.
inspection from ground Make entries of the observations in
level and keeping in check sheets/note book.
view the safe limits of
approach to live and
moving parts to check
apparent condition,
abnormal noise, rust on
body of the equipment
and component parts,
etc.)
2. Oil Level of Yes - - - Should be OK as per indicator if
Capacitors applicable. The indicator should be
kept clean and visible. Should be no
oil leakages
3. Oil Level of VT Yes - - - Should be OK as per indicator. The
indicator should be kept clean and
visible. Should be no oil leakages
4. HV Terminal Yes - - - Should be OK as per design and no
Connections (Line) hotspot/s (check during night
patrolling/thermovision survey)
5. Porcelain Bushing Yes - - - Should be clean and no damage
Condition
6. Supporting Structure - - Yes - Should be OK as per design, tight
Nut/Bolts/Level and secured
7. Ground Connections Yes - - - Should be OK as per design. Take
care of PLC connections if
applicable
8. Secondary Terminal Yes - - - Should be OK and no damage/no
Box: Cover, Cover defect, water proofing & vermin
locks, Cover packing, proofing intact
Cleaning, Proper glands
at wiring cable entrance,
Wiring cable
numbering, Vermin
proofing, Ground
connections, etc.
9. Secondary Terminal - - Yes - Should be tight and secured
Connections
Tests
10. DES test of Oil in - - - Yes DES value should be >30kV, 40kV,
VT (special test) 50kV at 2.5 mm gap for 66kV,
132kV, 220kV/ 500kV respectively

49
11. Chemical Analysis - - - Yes Should be as per laboratory
of Oil (special test) specifications
12. Tangent Delta (Tan - - - Yes As per laboratory specifications
δ) test of Oil (special
test)
13. Dissolved Gases - - - Yes As per laboratory specifications
Analysis (DGA) of oil
(special test)
14. Insulation - - Yes - Should be as per commissioning test
Resistance test (Megger results and/or specifications after
test) of Windings correction of test results at 20 °C
15. Capacitance and - - Yes - As per commissioning test results
Dissipation Factor test and/or specifications after correction
(C&DF test) of %DF results at 20 °C
16. Voltage Ratio and - - - Yes Should be as per specifications
Accuracy Test
Marshaling Kiosk/Cubicle
17. Doors, Door locks, Yes - - - Should be OK and no defect/damage
Door packing, Door
stops, Light, Cleaning,
Proper glands at wiring
cable entrance, Wiring
cable numbering,
Vermin proofing,
Ground connections, etc.
18. Space heaters & Yes - - - Should be intact and operative
Thermostat setting
19. Wiring and Terminal - - Yes - Should be tight and secured
Blocks

50
7. MAINTENANCE OF SURGE ARRESTERS/LIGHTNING ARRESTERS

500 KV Surge Arresters at 500 kV G/S NTDC Sheikhupura

SOP CHECK SHEET: MAINTENANCE SCHEDULE AND

CHECKS/TESTS OF SURGE ARRESTERS/LIGHTNING ARRESTERS
Description of Inspection Specified Time Period Remarks/Criteria/Standard/Safety

51
and Maintenance Work D/W M3/6 Y1 Y5- Precautions
10
1. Visual inspection (A Yes - - - Wear PPE and carry basic tools,
walk around visual multi-meter, clip-on-ammeter, etc.
inspection from ground Make entries of the observations in
level and keeping in view check sheets/note book.
the safe limits of approach
to live and moving parts to
check apparent condition,
abnormal noise, rust on
body of the equipment and
component parts, etc.)
2. HV Terminal Yes - - - Should be OK as per design and no
Connections (Line) hotspot/s (check during night
patrolling/thermovision survey)
3. Porcelain Bushing Yes - - - Should be clean and no damage
Condition
4. Corona Ring Condition Yes - - - Should be intact and secured
5. Supporting Structure - Yes - - Should be OK as per design, tight
Nut/Bolts/Level and secured
6. Ground Connections (at Yes - - - Should be OK as per design
L/A Base Plate, Operation
Counter and Steel support
Structure)
7. Operation Counter Yes - - - Should be OK as per design and
Condition and Reading operative
8. Leakage Current Yes - - - Should be OK as per design and
Monitor (Optional and operative along with remote
built in accessory in the indications
operation counter), Proper
glands at wiring cable
entrance, Vermin
proofing, Ground
connections, etc.
9. Insulators between L/A Yes - - - Should be intact and secured (an
Base Plate and Steel essential requirement for proper
Support Structure functioning of Operation Counter)
10. Insulation of Yes - - - Should be intact and secure (an
Conductor between L/A essential requirement for proper
Base Plate and Operation functioning of Operation Counter)
Counter
Tests
11. Insulation Resistance - - Yes - As per commissioning test results
test (Megger test) and/or specifications after correction
of test results at 20 °C
12. Capacitance and - - Yes - As per commissioning test results
Dissipation Factor test and/or specifications after correction
(C&DF test) (special test) of %DF results at 20 °C
13. Leakage Current - Yes - - Should be as per specifications and

52
Monitoring Test /or < 200 µA
14. Operation Counter - - - Yes Should be tested as per procedure in
Function Test the instruction manual and/or as per
conventional test procedure given in
the TSG Grid Maintenance Training
Book

8. MAINTENANCE OF BUS BARS

53
 `

132 kV Flexible Conductor Overhead Bus bar at 220kV G/S NTDC

Summandri Road Faisalabad

132 kV Tubular Pipe Overhead Bus bar at 220kV G/S NTDC NKLP Lahore

SOP CHECK SHEET: MAINTENANCE SCHEDULE AND CHECKS/TESTS OF

HV OUT DOOR BUSBARS
Description of Inspection Specified Time Period Remarks/Criteria/Standard/Safety
and Maintenance Work D/W M3/6 Y1 Y5/10 Precautions
1. Visual inspection (A walk Yes - - - Wear PPE and carry basic tools, multi-

54
around visual inspection meter, clip-on-ammeter, etc. Make
from ground level and entries of the observations in check
keeping in view the safe sheets/note book. Telescope/binocular
limits of approach to live is also useful for inspection of
and moving parts to check overhead bus bars.
apparent condition,
abnormal noise, rust on
body of the equipment and
component parts, etc.)
Flexible Stranded Conductor Bus Bar
2. Bus Bar Conductor Name / Rating: ------------------- Should be OK as per design and rated
/ ---------------- A capacity of G/S
3. Bus bar Conductor Yes - - - Should be OK and no damage
Condition (broken/damaged
strands, etc)
4. Bus Bar Conductor Sag or Yes - - - Should be OK and normal
abnormal side-tension
5. Disc Insulators Condition Yes - - - Should be OK, clean and no damage
(broken/chipped, etc ), Pins,
Clamps, Cotter-keys, etc.
6. Equipment Connections Yes - - - Should be OK and no damage, OK as
(Risers & Droppers) design and no hotspot/s (check during
night patrolling/thermovision survey)
Tubular Pipe/ Rigged Bus Bar
7. Bus Bar Pipe Size & Rating ---------------- ---------------- Should be OK as per design
A
8. Porcelain Support Yes - - Should be OK, clean and no damage
Insulators (broken/chipped,
etc)
9. Supporting Structure Yes - - - Should be OK as per design, tight and
Nut/Bolts/Level secured
10. Supporting Steel Yes - - - Should be OK as per design
Structure Ground
Connections
11. Flexible Connectors & - - - Yes Should be OK as per design, intact and
Slide Fittings secured
12. Equipment Connections Yes - - - Should be no damage, OK as per
(Risers & Droppers) design and no hotspot/s (check during
night patrolling/thermovision survey)

55