GOVERNMENT OF TAMIL NADU

ELECTRICAL INSPECTORATE

S.APPAVOO Thiru-Vi-Ka Industrial Estate,

Chief Electrical Inspector Guindy, Chennai-600 032.
to Government Phone: 2250 0184, 2250 0915
Fax:22500036;
www.tnei.tn.gov.in.

FOREWORD

Sophisticated life style, population explosion and industrial activities etc.

have necessitated the growth of electrical network. As a result, the electrical
installations are becoming more complex so as to cope up with the modern
machines, gadgets, multi-storeyed building activities etc. Since losses to the
personnel and property due to electrical accidents and electrical short circuit
initiated fires are also on the rise, it is of paramount importance to design and
execute the electrical installations observing proven principles of electrical safety
measures and complying with codes and regulations for ensuring safety.
I wish to state that it is always the collective responsibility of
manufacturers, consultant, contractors besides the statutory bodies to adopt the
procedures strictly in oredr ensure safe utilisation of Electrical energy.
I appreciate my deparment officials and members of Tanil Nadu Electrical
Installation Engineers’ Association who contributed a lot in bringing out this
edition which contains new concepts relating to safe work practises, Multi-
storeyed Building Installation, design aspects of earthing etc. with pictorial
representations for easy understanding. I also find that the guide lines has been
prepared deriving inputs from various Regulations, Codes, Standards and
observations of Inspecting officers in order to enable the consumers’ engineers
as well as contractors in understanding the regulatory requirements and adopt it
for the safe use of electricity, design and preparation of layouts and installation of
equipments starting from substation to final lighting circuit. The simple language
and sketches as well as tables at appropriate sections of varous chapters
enhances the easy understanding of the subject.
Since the areas where frequent flaws occur in the execution of electrical
installation has been treated with detailed write up, I am confident that this fourth
edition would make it an useful tool for the people in this sector.

20th March, 2015 ( S.APPAVOO)

1
2
 CHAPTER - 1

PROCEDURES

1. The procedures to be followed by the consumer in complying with

regulations and required technical standards for commissioning the
installation are covered in this chapter.

2. The following stages of compliances are involved in the commissioning of

an electrical installation

i. Obtaining Load Sanction from the TANGEDCO.

ii. Obtaining No objection certificate from the TANGEDCO, if the
proposal involves paralleling of Generator set(s) with
TANGEDCO’S grid.
iii. Obtaining Electrical Inspectorate’s approval for the drawing
proposal
iv. Erection and Completion of the Electrical Works based on the
drawings approved by the Electrical Inspectorate.
v. Submission of Completion Report for works completed.
vi. Rectification of defects pointed out after inspection and
submission of Rectification Report.
vii. Commissioning and Reporting
viii. Additions and Alterations to the existing installations

3. STAGES OF COMPLIANCE INVOLVED AT ELECTRICAL

INSPECTORATE

3.1 APPROVAL OF DRAWING

The following drawings are required to be sent to the Electrical

Inspectorate for approval:

a. Site Plan
b. Point of Supply and Sub-Station Layout
c. Schematic Layout
d. Physical Layout
e. Generator Layout
f. OH Lines Layout

3.1.1 Site Plan

A site plan showing clearly the following:

a. Topo plan showing the geographic location of the installation with

reference to the roads, village/town and land mark

3
 b. Boundary of the property with SF numbers, public road, canals or
entities other than the consumer, if any, within the boundary
c. Location of the supplier’s point of supply, viz; Location of supplier’s
structure/ RMG room along with the route of supplier’s HT incoming
OH lines /HT incoming cable
d. Location of consumer’s structure/HT gears near the point of supply,
Transformer, Generator and main panel room.
e. The route of the HT OH lines, if any, passing inside and adjoining the
premises.
f. Location of various buildings, Halls, sections etc.
g. Internal roads, clearance between the Transformer and its secondary
control gear.
h. In the case of Multistoried building of more than 15 Meter height,
planning permit letter and building elevation drawings approved by
the competent Local Planning Authority should be sent along with the
drawing proposal showing the set back clearance, drive way
clearance and clearance between the buildings in conformity with the
drawings approved by the Planning Authority.

3.1.2 Point of supply and Sub-station Layout

a. In case of Outdoor Substation, the following details should be

furnished in the drawings

i. Fencing around consumer’s and suppliers’ structure with the

location of entrance and the distance between the supplier’s pole
and the segregating fence provided for the supplier’s installation
from the consumer’s installation.

ii. Type and size of poles, pole to pole distance, arrangement of

jumpers, AB switch, H.G. fuse/D.O. fuse, Lightning arresters,
supporting channels, jumpers, HT cables, phase to phase
clearance, phase to earth clearance, safe working clearance, all
round clearance of the Transformers, position of transformer,
location and the size of earth leads, oil soak pit and its distance
from the substation etc.

iii. Distance from the Transformer to the primary and secondary

controls.

b. Soil resistivity test report, fault level calculation, data and calculation
for step and touch potential at the SS yard in the case of Power plant
and EHV sub station, protection against lightning, adequacy
calculation for the neutral earthing of the transformers, provision of
4
 high velocity water jet, nitrogen injection system for the fire protection
of transformer should be forwarded.

c. In case of Indoor sub-station, the following details should be furnished

in the drawings:

i. Location of supplier’s RMG unit with the all round clearance

provided for the RMG unit and size of HT cables.
ii. Cross-sectional views of the substation building indicating the
arrangement of transformer, segregating walls between
transformers, distance between the transformers and switchgears,
type of roofing, plan, section and elevation of bus duct and its
support, ventilation, oil soak pit and its distance from substation
etc. with all round clearances.
iii. Entrance and exit ways of main panel room, location of main panel
and any other switch boards at the main panel room with all round
clearances.
iv. Details of earthing and cable laying arrangement.

3.1.3 Schematic Layout

Single line schematic drawing should be furnished showing the complete

distribution of the entire installation right from the supplier’s installation
upto the final circuit of the consumer’s installation with the following
details:

a. Capacity and voltage rating of the Transformers, generators, type

(whether ACB/OCB/MCCB/MCB/FSU etc) and pole configuration
(whether 4 P/TP/ TPN/DP/SP) of the controls with setting
arrangements, CT ratio.
b. Size of Bus bars in main switch board, sub-switch boards, rating of
power distribution boards, Lighting distribution boards, motors,
capacitors and all loads, size of cables, rating and type of controls and
protection.
c. Change-over arrangement between generator source and grid supply,
the interlocking arrangement provided between the above with
operation sequence.

3.1.4 Physical Layout

a. Location of all switch boards, power distribution boards, lighting

distribution boards, motors, equipments etc. with reference to the
schematic layout.
b. All round clearances for the main panel and switch boards.
c. The symbols used in the physical layout should be explained under
legend column with notes column if required.
5
3.1.5 Generator Layout

a. Location of the Generators, control panels with all round clearances

b. Plan and section view of the Generator room.
c. Clearance between Generator and its control panel.
d. Arrangement of exhaust pipe, bus duct and details of earthing
arrangement.

3.1.6 O.H. Lines

Method of construction of the O.H. line, its size and type of conductor
material, with the details of supporting poles, span length, ground
clearances, clearance between phases, guarding arrangements,
control/protection provided etc. along with the calculation for factor of
safety of the supports.

3.1.7 General Observations

a. The drawings furnishing all the required details should be clear and
legible by proper font size.
b. All the drawings should be as far as possible of the same size,
uniformly folded to be easily spread-out for scrutiny. They should not
be big and unwieldy. Various equipments should be proportionate
though not to scale.
c. All the drawings should be given numbers and proper headings.
d. All relevant information relating to equipments/ installation/ erection
should be given under a suitable note/table/reference in each
drawing.
e. The connected load on each S.B. and D.B. should be indicated near
each board.
f. In the lighting distribution, maximum number of points and connected
load to each single phase final sub-circuit should be mentioned.
g. Anything that cannot be explained by symbols and lines should be
clarified with neatly lettered notes or explained as a write up.

3.1.8 Documents to be submitted along with drawings

a. An authorization letter obtained from the consumer authorising the

contractor to correspond with the electrical inspectorate.
b. The drawings should be signed by both the consumer and the
Electrical contractor who is doing the work.
c. Check list and Questionnaires for drawing approval should be duly
filled-up and signed. Model forms furnished below should be used:
6
 Check List (to avoid rejection at the submission level itself)

Enclosed by the
Sl. Consumer/
Item
No. Contractor (Tick
Yes or No)

1 Original Chalan for drawing scrutiny fee Yes/No

2 (i) Covering letter of the consumer Yes/No

(ii) Consent letter of the contractor Yes/No

3 Duly filled in questionnaire forms attested by consumer and Yes/No

contractor

4 Name of conusmer’s authorised signature and the authorization Yes/No

letter for the authorised signatory

5 4 sets of drawing duly signed by the consumer / contractor Yes/No

6 When the building comes under the category of MSB

(exceeding 15m in height)

(i) CMDA/DTCP building planning permit letter / approval Yes/No

drawing (Showing the Elevation and site plan)

(ii) Elevation view when the building is having G+3 floor Yes/No

7 Topo plan of the site (Showing survey number, boundary line of Yes/No
the site, near by public road adjacent site details etc.,)

8 (i) Soil resistivity test, fault level calculation, adequacy Yes/No

calculation for earthing the neutral of the transformers.
Calculation for step and touch potential at EHV yard,
calculation for protection against lightning, short circuit
calculation for buses of rating 33 KV and above.

(ii) The drawings showing the plan and sectional views of Yes/No
transformers, generators, SS yard, HV & MV panel rooms,
provision of high velocity water jet at SS yard in respect of
consumers availing EHV supply

9 Provision of HV breaker at the point of supply as per Regulation Yes/No

35

10 Whether the transformer erected inside the Multi Storied Yes/No

Building is dry type transformer

11 Whether the Diesel Generator is located at Ground floor or First Yes/No

basement.

Signature of the Consumer Signature of the Contractor

(Name) (Name)

7
 Questionnaire for Drawing Approval

1. (a) Name of consumer with Official Address to which ..

all Communications should be addressed

2. (b) Phone No. and Email of the Consumer

3. Location of HV Installation ..
(Full Particulars of the Taluk, Town, village and name of
street to be furnished)

4. Power requirement with Nature of load ..

5. Sanction of load with authority (Copy of the TANGEDCO ..

Letter)

6. Name and address of Contractor (with License details) ..

carrying out the installation and the Electrical supervisor
name with competency certificate No. who is directly
supervising the work.

7. Are all equipments and lines of the consumer proposed to ..

be erected entirely within the property of consumer?

8. Are all the materials and apparatus conform to the ..

relevant specifications and ISI?

9. Name, Residential address, telephone number of ..

Chairman/MD/Authorised signatory

10. Copy of memorandum and articles of association of the ..

company

11. Brief details of proposal ..

12. Technical: ..

Details of HV/EHV Installation ..

a. Substation (indoor/outdoor) ..

b. Transformer ..

c. H.V. Switchgear ..

d. H.V. Alternator ..

e. H.V. Motor ..

f. H.V. Capacitor ..

g. Other H.V. Equipments ..

h. Switch Gears Details of normal and rupturing ..

capacity should be furnished.

13. Details of M.V. Installation

a. Alternator ..

b. Motor and other equipments ..

c. Switchgear ..

8
14. Do all the equipments satisfy condition of the Supplier? ..

15. Distribution Mains If any (Details of Line Supports and ..

conductor size to be furnished).

16. Are these to be Erected Entirely within the property of the ..

Consumer

17. Drawing (in Quadruplicate, Signed by the consumer and ..

contractor) to be sent

a. Site Plan showing Point of supply, H.T. Installation ..

routes of Mains (O.H & U.G) & Topo Plan

b. Plan and elevation of Substation with clearance to ..

near by buildings or structures.

c. Schematic layout of the Equipments ..

d. Sectional elevation of switch gears with erection ..

details

e. Earthing Arrangements ..

f. If the Building height is 15 m and above, details of ..

Planning permit and drawing approval obtained
from the DTCP/CMDA authority

g. If the Installation is having building of G+3 floor and ..

above, Elevation drawing indicating the total height
of the building.

Whether Chalan for Adequate drawing scrutiny fee as per ..

G.O.30 is enclosed.

18. General ..

19. Have the Equipments been ordered? ..

If received details, if not received, probable date of
receipt.

20. Probable Date of Completion of Installation ..

21. (i) Date of last R43 inspection and copy of the defect ..
report.

(ii) Date of last R30 inspection and copy of the defect ..

report

(iii) Compliance of returns on electricity tax remittance ..

for consumption on self generation as well as sale
of energy.

(iv) Compliance of energy data filing in the case of ..

designated consumers under the Energy
Conservation Act, 2001.

Signature of Consumer Signature of Contractor

9
3.2 COMPLETION REPORT FOR THE INSTALLATIONS CARRIED OUT

3.2.1 The installation works should be carried out by a licensed Electrical

Contractor under the supervision of a person holding a Certificate of
Competency as prescribed in the regulation 29 of Central Electricity
Authority (Measures relating to Safety and Electric Supply), Regulation,
2010, in accordance with Central Electricity Authority (MSES) Regulation,
2010, Bureau of Indian Standards, applicable codes and practices and as
per the General and Specific Conditions & Remarks stipulated in the
drawing approval.

3.2.2 After carrying out the installation works, a completion report should be
forwarded to the Electrical Inspectorate along with the following:

a) A challan for having remitted the required inspection fees.

b) Copy of the load sanction letter issued by the Supply authorities.

c) Report on the completion of Supplier’s portion of installation for

effecting service connection.

d) Copy of appointment letter of authorised Electrical Supervisor and

his consent letter with the Certificate details under regulation 3 of
Central Electricity Authority (MSES) Regulation, 2010.

e) Completion Report prepared in a standard format as prescribed in

I.S. 732.

f) Report of compliance of item wise conditions stipulated in the

drawing approval.

g) Manufacturer’s original test certificates (with two copies) for the

E.H.V. and H.V. equipments, Transformers, Switchgears, Cables,
Generators, Motors, Bus-duct, appliances. Pre-commission test
reports in the case of equipments which were kept idle for a period
of more than six months. In the case of equipments which had
undergone repairs, etc., HV test should be conducted and Test
Certificate should be furnished with the knowledge of the Electrical
Inspector.

h) List of equipment details (department/section wise) furnishing the

following details:

i. Name plate details of HV and EHV equipments, gears,

panels, cables, bus ducts etc.

ii. Rating in HP/kW/kVA/kVAr, Voltage and feeder details in

respect of generators and loads

10
 iii. Details of Switch boards and DBs

iv. Deviations in the rating, circuitry arrangement and location

change from the approved drawings.

3.3 INSPECTION

3.3.1 The next stage is inspection by the Electrical Inspectorate under the CEA
regulations.

3.3.2 At the time of inspection, a responsible representative of the consumer,

the Electrical Supervisor who has signed the completion report and the
representative of the Contractor should be present with their license and
measuring instruments.

3.4 RECTIFICATION OF DEFECTS AND OBTAINING PERMISSION

i. All the defects intimated, after the inspection by the Inspectorate

should be rectified and report should be sent thereon.

ii. The Electrical defects, if any, pointed out at the time of inspection
should be rectified and a detailed item wise Rectification Report sent
to the Electrical Inspectorate through the Consumer.

3.5 COMMISSIONING AND REPORTING

3.5.1 Once the permission is issued by the Electrical Inspectorate after

ensuring compliance, the consumer may arrange to get the installation
energized in consultation with the Supplier.

3.5.2 The date of commissioning of the installations should be reported to the

Electrical Inspectorate by the consumer.

3.5.3 In cases where the commissioning of installation was not done before the
expiry of validity of permission issued by the Electrical Inspectorate,
application with required documents as deemed necessary by the
Electrical Inspectorate should be submitted and the permission should be
got revalidated before energisation.

11
 CHAPTER - 2

SWITCHYARD AND SUBSTATION

A. POINT OF SUPPLY
1. General

a. Adequate space should be provided for the point of supply and the
Supplier’s installations for effecting service connection, in consulta-
tion with the Supplier.

b. The D.P Structure yard should be located higher than the flood level
and also higher than the surrounding ground level to prevent water
logging.

c. The outdoor structure yard should be uniformly leveled and spread

with 38 mm blue granite jelly to a depth of 15 cm over a layer of
sand.

d. In the case of outdoor structure being provided by the Supplier, the

consumer should provide the consumer’s outdoor structure at a
distance of not less than 4.575 metres from the Supplier’s structure
for 11kV, 22kV & 33kV systems.

e. The Supplier’s installations at the point of supply should be

segregated from the consumer’s installations using suitable fencing
or fire partitioning wall as the case may be in consultation with the
supplier.

f. The supplier’s outdoor structure and consumer’s apparatus should be

segregated by providing fence at a distance of not less than 1.525 m
from supplier’s structure.

g. Fencing should be provided for the outdoor structure yard upto a

height of not less than 1.8 m with a suitable gate and lock.

h. Fence should be earthed properly, preferably, using 8 SWG copper

and the gate should be properly earthed using flexible/braided
copper leads.

2. Structure Material

a. The D.P. Structure should be of RSJ pole with concrete foundation.

RSJ pole should not be of cut and welded joints and it should be of
single piece.

b. The size of the RSJ pole should be 200mm x 100mm in case of 11kV
and 22 kV system.
12
 c. The base of the poles forming the outdoor structure should be
concreted and coping done to a height of atleast 45 cm from the
ground level.

3. Jumper

a. The minimum size of H.V. Jumper at the outdoor structure should be

of ‘O’ SWG copper.

b. The unsupported length of Jumper at outdoor structure should not be

more than 1.5m in the case of solid copper.

c. All the jumpering should be in one vertical alignment with minimum

bends. The shape of the jumpers should be uniform.

d. The H.V. Jumper at the outdoor structure should be so aligned that

the drop out fuse unit (DOF) does not hit the jumper while the DOF
cartridge drops.

e. Bimetallic clamps should be used for connecting copper jumper to

Aluminium jumpers/wires.

4. AB Switch

a. The A.B. Switch should be mounted below the incoming OH strung

bus of the Supplier at the consumer’s structure.

b. The A.B. Switch should be erected in such a way that the incoming
supply is received at the fixed contacts of the AB switch.

c. The blades of the AB switch should open fully to ensure that

adequate gap is available for avoiding accidental charging by birds.

d. The operating down pipe of the AB switch should have suitable

guides and the handle should be positioned at a height of not less
than 1.068 metres from the ground level for convenient operation.

e. Lock should be provided for the operating handle of the A. B. Switch.

f. The handle of the A.B. Switch should be earthed using

flexible/braided copper.

g. Mechanical interlocking arrangement should be provided between

the A.B. Switch and respective HT breaker at the point of supply so
that the A.B. Switch can be operated only when the breaker is in OFF
Position.

13
5. Lightning Arrester

a. Lightning Arrester should be connected after the A.B. Switch.

b. Earth flat of the lightning arrester should be inter-connected with

other earth electrodes.

c. Copper conductors should be used as earth flat for the lightning

arrester.

d. i. Lightning Arrester should be positioned close to transformer so

that the length of earth flat and its reactance during steep wave
front does not harm Lightning Arrester’s itself as well as the
equipment to be protected by efficient dissipation of surges.

ii. The earth flat should not have much bends so as to avoid
increased reactance during surges.

6. Stay Wire

a. D.P. Structure should be provided with suitable stay. Each stay wire
should be earthed unless an insulator has been placed in it at a
height of not less than 3.0 metres from the ground. The stay wire
shall be of stranded G.I. wire and the stay rod should be grouted by
concrete muffing.

7. Clearances

a. The Vertical clearance between H. G. Fuse mounting channel and

the live parts of A. B. Switch should not be less than 2.13 metres.

b. The minimum creepage clearance between any live parts/jumper and

any earthed metal parts on the structure including cable boxes
should be 30 cms for 11 KV, 45 cms for 22 KV and 60 cms for 33
KV.

c. H.G. fuse gap should be 20cm for 11 kV, 25 cm for 22 kV and 30 cm

for 33 kV.

d. The safe working clearance between any wall/building/ground and

the nearest live conductor should be as follows:

Highest System 12 36 72.5 145 245 420 800

Voltage (kV)
Safety Working 2.6 2.8 3.1 3.7 4.3 6.4 10.3
Clearance (metres)

14
 e. The clearances in respect of outdoor switch yard and sub station are
furnished in the following table:

Switch yard and point of supply

Switch yard clearance details

11KV 22KV 33KV 110KV 230KV

Dimensions Dimension Dimension Dimension Dimensions

in mm s in mm s in mm s in mm in mm

Bay width 3050 3660 4576 8840 12200

(Pole to
pole)

Phase to 915 1068 1220 1675 3350

phase

Phase to str. 610 762 1068 1000 1675

Poles

Jumper size ‘0’SWG ‘0’SWG 19/0.083 ACSR 1.1026”dia

cu Goat
(0.25” Dia) (0.625”
Dia)

Cross 100x50x6 100x50x6 125x65x6

channel

Tubular bus 1½OD 1½OD 2”Odcu/Al 3”cu clad 3”IPS Al.

size cu/Al cu/Al steel/Al

RSJ/Tower 200 x 100 200 x 100 200 x 100 65 x 65 x 6

size angle
for leg
member &
45 x45x 6
for lacing

Pole length 9145 9145

Base plate 300x300x6 300x300x6 300x300x6

size MS MS MS

Pole height 1/6 of pole 1/6 of pole 1/6 of pole

below
ground level

15
 f. The following Table may be referred for ensuring adequacy of
conductors used for interconnection etc. at the switch yards

ACSR – Aluminium Conductor Steel Reinforced.

Cable Name Std. nominal Size Current for Temp.
Copper area rise of
mm2 30o C 50o C
Mole 6.5 7/1.50 42 56
Squirrel 13 7/2.11 70 97
Gopher 16 7/2.36 88 109
Weasel 20 7/2.59 100 125
Ferret 25 7/3.00 125 155
Rabbit 30 7/3.35 148 183
Mink 40 7/3.66 167 208
Beaver 45 7/3.99 189 235
Raccoon 48 7/4.09 197 245
Otter 50 7/4.22 207 257
Cat 55 7/4.50 229 285
Dog 65 6/4.72+7/1.57 254 311
Leopard 80 6/5.28+7/1.76 286 367
Wolf 95 37/2.59 343 423
Lynx 110 37/2.79 385 475
Panther 130 37/3.00 427 526
Lion 140 37/3.18 465 574
Bear 160 37/3.35 506 623
Goat 185 37/3.71 586 724
Sheep 225 37/3.99 655 808
Kundah 250 42/3.50+7/1.94 696 863
Drake 250 26/4.42+7/3.454 710 875
Zebra 264 61/3.18 720 890
Deer 264 37/4.27 726 896
Crane 280 61/3.233 770 925
Elk 300 37/4.50 787 970

16
 g. The following Table may be referred for ensuring adequacy of
conductors used for interconnection etc. at the switch yards

Current carrying capacity of O.H. conductors (Solid copper conductors)

SWG Dia Nominal Current rating

Sectional For Temp rise of
Area
27.8o C 55.5o C
(50o F) (100o F)

Inch Sq.in Amps Amps

10 0.128 0.01287 37 50

9 0.144 0.01629 44 60

8 0.160 0.02011 52 70

7 0.176 0.02433 58 81

6 0.192 0.02895 68 92

5 0.212 0.03530 78 107

4 0.232 0.04227 91 122

3 0.252 0.4988 103 139

2 0.276 0.5983 117 158

1 0.300 0.07069 133 181

1/0 0.324 0.8245 150 203

2/0 0.348 0.9511 167 226

3/0 0.372 0.10870 184 250

4/0 0.400 0.12570 205 278

This table refers to situation where the initial temp of the Air is 49 o C (120o F). In
the case of braided aerial conductors the ratings given for a temp rise of 27.8 oC
(50oF) should be taken. It is also usual to work to this temp for bare conductors.

17
18
 CHAPTER – 2

B. SUB STATION

1. The Sub-Station, being a nerve centre, calls for a detailed and elaborate
consideration and study.

1.1 Basic Location Selection Criteria

1.1.1 The substation should preferably be located in separate building and

could be adjacent to the generator room, if any. Location of substation in
the basement floors should be avoided.

1.1.2 The Sub-Station may be located as far as practicable at the load centre
to avoid excessive voltage drop and consequent losses by the reduced
length of the M.V. Cables, thereby reducing the project cost and for
achieving efficient operation and maintenance.

1.1.3 The location should take into consideration the direction and movement
of dust etc. in Cement, Carbide factories and Textile Mills etc.

1.1.4 The Sub-station should be located higher than the maximum flood level
of that location and also higher than the surrounding ground level to
prevent water logging

1.1.5 Outdoor Sub-Station may be avoided in the following areas:

a. Corrosive atmosphere as in Chemical factories.

b. Near sea-coast
c. Polluted and smoky areas in Cement Plant and foundries etc.
d. Close proximity to spray-ponds, dusty areas, cooling towers and
chimnies.

1.1.6 The sub-station should have direct access from the road for installation or
removal of the equipment.

1.1.7 Enough space should be provided for accommodating future expansion.

Adequate passage ways for transport of equipment for repairs should be
provided.

1.1.8 The environment should be clean and tidy. It should not be located near
refuse dumps, lavatories, scrap heaps or space above drainage and
sump.

1.1.9 Water and other drains should not pass through or be terminated at the
sub-station.

19
1.1.10 Storm water draining arrangement should be provided for the switch yard
and sub-station for an effective draining of storm water to the natural
drain.

1.1.11 Sub-station should be used to house the intended equipments only.

Storage of any other materials and any repair work should not be
permitted therein.

1.1.12 The distribution transformer rooms (HV & EHV), generator rooms, switch
gear rooms, etc should be provided with wall ventilators at roof level. The
total area of the ventilators should be atleast one percent of the floor area
of the room. The doorways should be fitted with grilled type rolling
shutters to facilitate cross ventilation.

1.1.13 The substation should be provided with lightning and surge arrestor in
order to provide protection against lightning and line surges.

1.2 Design Consideration

1.2.1 Transformer

1.2.1.1 The rating of the transformer should be carefully selected, keeping in

view the anticipated maximum demand, connected load, diversity factor,
in-rush current of large capacity motors, etc.

1.2.1.2 The no-load secondary voltage rating of the transformer should be as per
relevant I.S.

Typical approach for arriving at the Transformer Sizing

a) Maximum Demand in kVA

b) Rating of transformer required (Allow 10% design margin) to meet the
steady state condition = a / 0.9
c) Rating of the largest motor in kW
d) Steady State kVA of the Largest Motor = c / (eff x pf)
e) Starting kVA taken by the largest motor during starting (e.g. star-delta
starter) = d X 3
f) Base kVA before the starting of the largest motor = a-d
g) Dynamic Load = Largest Motor kVA during Starting+Base kVA = e + f
h) Rating of Transformer to withstand the above dynamic load
(Transformer can withstand 150% overloading for 15 seconds) = g / 1.5
Minimum Transformer Rating Required = h or b whichever is higher
Next Available Standard Rating is to be chosen

20
1.2.1.3 The rating of the Transformers should be as per BIS and the
transformers should be erected as per BIS 10028.

1.2.1.4 It is preferable to install the transformer outdoor for better cooling effect,
which will enhance the life of the transformer. If the other considerations
outweigh and an indoor sub-station preferred is preferred, efficient forced
ventilation is a must. The oil filled Transformer should be erected at the
ground floor of the utility building only except the transformers like
furnace transformer, rectifier transformer etc., being integral part of the
equipment.

1.2.1.5 The transformer room should be well ventilated. Suitable provision for
entry of adequate fresh air should be made. Where natural cross
ventilation is not adequate, nor feasible, exhaust fans should be
provided. The rolling shutters should be of grilled type. Doors, windows
and ventilators should be made of non-inflammable materials only.

1.2.1.6 The breather should be well supported. Cooling fins of the transformer
should not be used for supporting the breather. The maximum
permissible temperature should be permanently marked on the Dial type
Thermometer.

1.2.1.7 The transformer plinth should be of correct size to accommodate the

transformer so that no person may step on the plinth and inadvertently
come close to the live parts.

1.2.1.8 Four Pole Structure

a. In an outdoor 4 pole structure arrangement, not more than 2

transformers should be provided. Where more than two transformers
are required, 6-pole or suitable structure be provided.

b. If the transformers are installed in opposite sides of the structure,

phase sequence reversal is inevitable. In such cases, the vector
group of Transformers may be of DY 11 and DY1. Any two leads of
the secondary side of DY1 transformer should be interchanged at the
secondary breaker to ensure correct phase sequence.

1.2.1.9 Protection

a. Over current protection should be provided to disconnect the supply

automatically if the rated current of the equipment, cable or supply
line is exceeded for a time which the equipment, cable or supply line
is not designed to withstand

b. Earth fault or earth leakage protection should be provided to

disconnect the supply automatically if the earth fault current exceeds

21
 the limit of current for keeping the contact potential within the
reasonable values

c. Gas pressure type and winding and oil temperature protection to give
alarm and tripping shall be provided on all transformers of ratings
1000 kVA and above

d. Transformers of capacity 10 MVA and above shall be protected

against incipient faults by differential protection

1.2.1.10 Paralleling of Transformers

Where it is desired to operate two or more transformers in parallel, they

should possess the following principal characteristics for satisfactory
parallel operation:

a. The same inherent phase angle difference between primary,

secondary voltage.
b. The same voltage ratio and vector group
c. Percentage impedance with minimum difference
d. The same polarity
e. The same phase sequence
f. The disparity in outputs of any two transformers should not exceed
three to one.
g. Paralleling of transformers should be done only on the Main M.V.
Switch Board.

1.2.1.11 General Clearances

a. Both the primary and secondary control gears of the transformer for
indoor or outdoor, as the case may be, should be easily and directly
accessible and as close as possible, say within 15 metres as from
transformer to MV Panel.

b. The structure supports and their spacing’s, jumpering and their

clearances and details of A.B. Switch/H.G. Fuse/D.O. Fuse, etc.
should be as described in Chapter - 2. The cross channels should be
of adequate strength.

c. A clear space of not less than 750mm should be provided around the
transformer as measured from the farthest part of transformer to the
nearby walls, structure supports etc.

d. The Indoor Transformer room should have sufficient head room

clearance from the top most fittings of the transformer to the ceiling to
facilitate easy removal of fittings such as conservator tank, core, etc.
22
 e. The following safe working clearances should be maintained for
supplying, converting transforming or using at voltage exceeding
650V:

Highest System 12 36 72.5 145 245 420 800

Voltage (kV)
Safety Working 2.6 2.8 3.1 3.7 4.3 6.4 10.3
Clearance (metres)

1.2.1.12 Fire Safety Measures

a. Every oil-filled apparatus, such as transformer, static condenser,

switchgear or oil circuit breaker having an individual or aggregate oil
capacity of 2000 litres or more shall be housed in a locked, weather
and fire resistant building and shall be properly ventilated to the
outside of the building only. The building housing the oil-filled
apparatus shall be separated by a distance of not less than 6 m from
all other buildings.
Note:

i. If the building housing the transformer is within 6 m of the surrounding

building there shall not be any door or window opening in the substation
or the surrounding building.

ii. If the building or compartment housing oil-filled apparatus is

communicating with another building or compartment, the substation
shall be segregated by separating walls of 355 mm thick brick wall or
230 mm thick RCC, carried up to roof level with door openings therein
protected by single fireproof doors of 2 h rating.

iii. Not withstanding the above, if the substation supplies power to fire
pumps, the same shall be segregated from the adjoining building by 400
mm thick brickwall or 300 mm thick RCC wall without any door opening
therein where, however, door openings are absolutely necessary, the
openings shall be protected by double fire resisting doors of 2 h rating
each.

iv. If the substation is attached to a storeyed structure, in addition to the

above segregations, it will also be necessary for the substation to be
provided with RCC slab roof.

b. Each oil-filled apparatus, such as transformer, bank of static

condensers, including high tension circuit breakers, switch and main
distribution boards, having an individual or aggregate oil capacity of
2000 litres, shall also be segregated from all other apparatus by 355
mm thick fire resisting brick wall or 230 mm thick RCC. The
separating wall shall be carried right up to the roof level unless the

23
 roof is more than 3 m above the highest point of the equipment, in
which case the wall shall be carried up to a height at least 600 mm
above the top of the equipment so separated.

i. The above provisions need not be applied to furnace and rectifier

transformers as also to transformer of testing apparatus or other
equipment of which the transformer is an integral part, whether
they are oil-filled or not.

ii. The requirements given under this rule, however, do not apply to
dry type transformers, or transformers having sulphur
hexafluoride, non-flammable coolants and having primary
voltage not more than 33 kV.

iii. If dry type transformer is used, substation may be located

adjacent to medium voltage switchgear in the form of unit type
substation. No separate room or fire barrier for the transformer is
required, in a substation with oil free equipment.

c. Transformers and equipment installed outdoors, having an individual or

aggregate oil content of 2000 litres or more shall be located in a suitably
fenced and locked enclosure separated on all sides by at least 6 m from
any building including substation. Separating walls are necessary
between transformers having an individual or aggregate oil content of
2000 litres.
Note:
i. There should be no door or window opening in the surrounding
building, if the transformers are within 6 m thereof.
ii. If the transformers are within 6 m of doors and window openings of
surrounding buildings then they shall be protected by single fire proof
doors and 6 mm thick wired glass in steel frames respectively.
iii. Separating walls shall not be necessary in case of transformers
having an aggregate oil capacity exceeding 2000 litres but individual
oil capacity of less than 5000 litres if the distance between
transformers and other apparatus is more than 6 m or if the
transformers ate protected by an approved high velocity water spray
system.
iv. Where however oil capacity of individual transformer is larger than
5000 litres separating walls shall be provided unless all
equipment/building/plant are located at a clear distance of not less
than the following:

Oil Capacity of Individual Clear Separating

Transformer Distance
5000 – 20000 litres 8 metres
Over 20000 litres 15 metres

24
 d. Transformers of 10 MVA and above rating or in case of oil filled
transformers with oil capacity of more than 2000 litres shall be
provided with automatic high velocity water spray system as per
relevant IS 3034:1993 or Nitrogen Injection based Fire Protection
system. The transformers or reactors of 220kV or higher voltage may
preferably be provided with Nitrogen Injection based Fire Protection
system in addition to automatic high velocity water spray system.

1.2.1.13 Oil Soak Pit

a. In order to reduce the risk of spreading fire, transformers containing

2000 litres or more of oil shall be provided with transformer oil soak
pits filled with suitable size of gravels or pebbles below each
transformer with voids of capacity adequate to contain the total
quantity of oil in the transformer.

b. Alternately common burnt oil pit of adequate capacity (atleast equal

to oil quantity in the largest size transformer) shall be provided for a
group of transformers connected to all the soak pits of the
transformers with 150 mm in diameter drain pipe for fast draining of
oil or water from soak pit to the burnt oil pit.

c. Every soak pit below a transformer shall be suitably designed to

contain oil dropping from any part of the transformer. The burnt oil pit
should be provided with suitable automatic pumping facility so as to
keep the pit empty for use during emergency.

d. The oil soak pit shall be located not less than 2.5 m away from the
substation. Floors shall be sloped to not less than 1 in 96 towards oil
drain.

e. Care should be taken to seal openings including cable trenches and

cable entries inside the transformer room (near transformer/
switchgear) so as to prevent oil seepage into the cable trenches.

25
Typical Oil Soak Pit Arrangement

26
1.2.2 Bus Ducts

a. In case of transformer/generator, where the capacity is 750 kVA and

above, bus-duct should be provided on the secondary side of the
transformer/generator.
b. The bus-duct as well as its support should not infringe the clearances
provided. If necessary the support may be provided from the ceiling.
c. Where it crosses a passage way, there should be a clear head room
of 1.8 metre below it.
d. The bus-duct should be supported separately so as to avoid strain on
the transformer/generator.
e. The bus-duct should be as short as possible with minimum bends.
Where the bus duct is more than 4.5 metre long, expansion
joint/connector may have to be provided to prevent the terminal
bushing being unduly stressed due to expansion.
f. The opening in the wall around the bus duct should be closed by
non-flammable material or plastered without gap.
g. Outdoor bus ducts to be provided with proper canopy to avoid water
stagnation.

1.2.3 Controls

a. Control gears recommended to be provided for the transformers at

various system voltage are furnished at the following sketch:

27
System Transformer Group control Primary Control for
Voltage Capacity or control at the individual Transformer
point of supply capacity
Upto 1000 kVA AB Switch with
aggregate or Fuse or circuit
Individual breaker
Above 1000 kVA Circuit breaker a) AB Switch with fuse or
aggregate or circuit breaker for the
individual capacity of less than
1000kVA
b) Circuit breaker for the
11 kV capacity of 1000kVA and
System above
Up to 2500kVA AB Switch with
aggregate or Fuse or circuit
individual. breaker
Above 2500kVA Circuit Breaker
22kV or aggregate or
33kV individual

Above Any capacity Circuit Breaker Circuit Breaker

33kV

Note:
i. Circuit breaker alone is permitted on the secondary side of all
Transformers.
ii. All circuit breakers should be of draw out type.
iii. Where the point of supply and consumer apparatus near each other
one linked switch with fuse or circuit breaker near the point of
commencement of supply shall be considered sufficient.

b. The Circuit Breaker (Draw out type) with EFR with proper CT ratio
provided on the secondary side of the transformer should be of correct
rating.

c. Where transformers protected by H.G./D.O. fuses are intended for

parallel operation, interlocking arrangement, preferably mechanical type
should be provided between H.V. & M.V. Control Gears to avoid back-
feeding and for safe renewal of fuses in the outdoor yard and for safe
maintenance work on individual transformers.

d. In an outdoor structure, D.O. Fuses should be preferred when more than

one transformer is erected for safe renewal of fuses. Adequate section
clearance should be provided, if H.G. fuses are used.

e. The rated rupturing capacity of Making and breaking capacity of the

switch-gear should commensurate with short circuit potentialities of the
supply system and the ‘Supply authorities’ should be consulted on this
subject.
28
 f. Generally the minimum rupturing capacity of H.V. & M.V. Circuit Breakers
at different voltages should be:

System 11 or 22 33 66 110 220 400 765

Voltage (kV)

Minimum Not less Not less 31.5kA 31.5kA 40kA 40 or 40 or

Rupturing than than 50kA 50kA
Capacity 25kA 25kA
(kA for 1s)

1.2.4 Cables

a. The main incoming H.V. Cable to the group control Circuit Breaker
should be designed keeping in view not only the full-load current, but
also the prospective fault level of the locality and in any case should
not be less than 185 sq. mm size for XLPE. All other H.V. cables
should be of adequate size.

b. The M.V. Cables on secondary side of the transformer/generator

shall be designed to take care of the full load current of the
transformer/generator and should normally be as follows:

Transformer rating in
PVC aluminum cable size(armoured)
KVA (433V)
100 One run of 31/2 core 95sq.mm
150 One run of 31/2 core 185sq.mm
160 One run of 31/2 core 240sq.mm
200 One run of 31/2 core 300sq.mm
250 One run of 31/2 core 400sq.mm (or)
Two runs of 31/2 core 185sq.mm
315 One run of 31/2 core 300 sq.mm XLPE
400 Two runs of 31/2 core 300sq.mm XLPE
500 Three runs of 31/2 core 300sq.mm XLPE
630 Four runs of 31/2 core 300sq.mm XLPE
750 & above Bus bar trunking

29
M. V. Alternators
PVC Aluminum cable size (armoured)
(415V)
110 One run of 31/2 core 95sq.mm
160 One run of 31/2 core 240sq.mm
200 One run of 31/2 core 300sq.mm
250 Two runs of 31/2 core 185sq.mm PVC or
One run of 31/2 core 300sq.mm XLPE
320 Two runs of 31/2 core 185sq.mm XLPE
550 Three runs of 31/2 core 300sq.mm XLPE
625 Four runs of 31/2 core 300sq.mm XLPE or
Three runs of 31/2 core 400sq.mm XLPE
750 Bus Bar Trunking

30
 CHAPTER – 3

EARTHING PRACTICES

1. Earthing should confirm to the requirements of Central Electricity

Authority Regulations, 2010 and BIS: 3043.

2. DP Structure Earthing

a. The poles, metal frame work, metallic base of the A.B. Switch, D.O.
Fuse/H.G. Fuse, pin insulators etc should be earthed effectively using
25 x 3 mm copper or its equivalent G.I. Conductor.

b. The operating down pipe and operating handle of the A.B. Switch,
support shall be earthed effectively using braided copper earth lead .

c. The earth flats of the lightning arresters should be of 25 x 3 mm

copper and shall be taken as directly as possible along the structure
and suitably secured.

d. All the sections and cross-lacings of the fencing shall be bonded

electrically and connected to the earth grid of the SS yard effectively.

3. Transformer/Generator Earthing

a. The frame of every Generator, stationary motor, portable motor and

the metallic parts, not intended as a conductors, of all Transformers,
H.V. Switch-gears/M.V. Switch Boards/control panels and any other
apparatus used for regulating or controlling electricity shall be earthed
by two separate and distinct earth connections.

b. In case of outdoor type transformer with bushings, the top cover and
tank of the transformer should be looped using adequate size of
copper strip to avoid passing of fault current through the fastening
bolts and to provide a current carrying path in case there is a flash-
over on the terminals of the bushings.

c. Suitable link should be provided in the neutral earth flat to temporarily

interrupt the neutral connection for the purpose of testing or locating a
fault.

d. No fuses or circuit breakers other than a neutral link shall be inserted

in the neutral earth flat.

e. The neutral of transformers/generators shall be earthed by not less

than two separate distinct earth connections.

31
 f. The neutral earthing of Transformers/generators should be generally
done as per table and sketch shown below:

Generator/ Insulated (PVC) Galvanized Iron

Electrolytic Bare
Transformer Single core conductor or
copper
Rating Stranded AL strip
50KVA & 8 SWG 16 sq. mm 25 × 3mm
BELOW
75 KVA 6 SWG 25 sq. mm 40 × 6mm
100 KVA 4 SWG 35 sq. mm 40 × 6mm
150 KVA 2 SWG or 70 sq. mm 40 × 6mm
25 × 1.5mm
200 KVA 25 × 3mm 95 sq. mm 40 × 6mm
250 KVA 25 × 3mm 150 sq. mm 40 × 6mm
300 KVA 25 × 3mm 225 sq. mm 40 × 6mm
500 KVA 25 × 6mm 300 sq. mm 40 × 6mm
630 KVA 40 × 6mm 2 × 225 sq. mm or *
1 × 500 sq. mm
800 KVA 40 × 6 mm * *
1000 KVA 50 × 6 mm * *
1250 KVA 60 × 6 mm * *
1600 KVA 80 × 6 mm * *
(or 50 × 10mm)
2000 KVA 60 × 10mm * *
2500 KVA 75 × 10mm * *

Note:

* The size of the earth flats should be arrived as per BIS 3043. Reference is
furnished in the Chapter, “Earthing Design” under the head “Adequacy of
Earthing Conductor”.

However while referring the above table, consideration of fault level at the
point of application, type of earthing system, earth electrode configuration
etc should also be taken in to account.

32
 Equipment Earthing - Size of Earth Lead
(Transformers, Motors, Generators, Switchgears etc.,)

Rating of 400V Size of Earthing Conductor

30,50Hz equip AL PVC Galvanised
Bare Copper
In kVA Insulated Iron Conductor
Upto 5 10 SWG 10 Sq.mm 7/22
5 to 15 10 SWG 16 Sq.mm 6 SWG
15 to 50 8 SWG 16 Sq.mm 1”x1/16”(25x1.5mm)
51 to 75 6 SWG 25 Sq.mm 1”x1/16”(25x1.5mm)
75 to 100 6 SWG 35 Sq.mm 1”x1/8”(25x3mm)
101 to 125 4 SWG 50 Sq.mm 1”x1/4”(25x6mm)
126 to 150 2 SWG OR 70 Sq.mm 1”x1/4”(25x6mm)
1”x1/15”(25x1.5mm)
151 to 200 1”x1/15”(25x1.5mm) 70 Sq.mm 1”/2”x1/4”(40x5mm)
200 and above 1”x1/8”(25x3mm) 185 Sq.mm 2”x1/4”(50x6mm)
Note:
1. Conductor to be protected so that no mechanical damage could be caused. Earth
connections for all H.V.motors and SW gears should be not less than 0.1 sq.mm
inch copper tape or 185 sq.mm PVC insulated stranded al conductor or
2”x1/4”galvanised strip
2. However while referring the above table, consideration of fault level at the point
of application, type of earthing system, earth electrode configuration etc should
also be taken in to account.

33
34
35
4. Switchboard and Switchgear Earthing

a. The draw-out type circuit breaker should be earthed by suitable sliding

type earth.
b. The potential transformer in the circuit breaker shall be earthed by
sliding type earth or short length of braided copper earth lead.
c. The metallic base of the each switch-fuse unit and fuse switch unit in
the main switch board /Switch board should be provided with separate
earth connections. Looping of earth wire from one switch to another
should be avoided. An earth flat of adequate size should be provided
along the entire length of the switch board and either ends of the earth
flat shall be connected to system earth. Further, the earth leads for all
controls shall be connected to the above said earth flat.
d. Metallic parts of fuse distribution boards, MCB distribution boards,
isolators, starters and any other apparatus used for controlling and
regulating electricity should be earthed effectively.
e. Earth flat should be run along the entire length of the Bus Bar
Trunking (BBT) / bus duct and the ends of the earth flat shall be
connected to system earth.

5. Other Equipment Earthing

a. The fourth core of the supply lead intended for the overhead crane
should be used as earthing conductor of the Crane Motors. Further the
earthing should be ensured electrically and mechanically continuous
throughout the entire length of the metallic rails.

b. The armour of the cables, the cable glands, metallic cover /metal
conduits, any other metal parts associated with the electricity should
be effectively earthed.

c. All portable apparatus should be earthed by the use of 3 pin or 4 pin

plugs as the case may be. The third pin of the 3 pin socket and the 4 th
pin of the 4 pin socket outlets should be connected to earth.

d. Earth conductor, risers of air conditioning systems, heating systems,

metallic parts of buildings., etc should be interconnected to maintain
equipotential bonding.

36
 e. The earth flat should be protected against mechanical damage.
Precautions should be taken to avoid corrosion of earth leads and
earth bus in corrosive areas like Chemical Plants.

f. All earth connections in the straight run can be bolted, riveted, welded
or brazed above ground surface. However, below ground all
connections should be vibration free either brazed or welded. The
earthing system should be mechanically robust and joints should be
capable of retaining low resistance even after passage of fault current.
Earth leads/earth bus should not be connected to water mains.

g. The earth leads laid on the floor should always be embedded into the
floor and it should not be exposed on the floor.

6. Earth Electrode Construction and Maintenance

a. Earth electrode is a conductor burried/embedded into the earth for

minimizing the ground potential through conductors connected to it and
for dissipation of the earth fault current conducted to it.

b. The earth electrode should conform to the BIS 3043.

c. Although electrode material does not have much influence on the initial
earth resistance, care should be taken to select a material which is
resistant to corrosion in the type of soil in which it is used so as to
avoid deterioration of earth resistance values.

d. It is recommended to use similar material for earth electrodes and

earth conductors or otherwise precautions should be taken to avoid
corrosion and bimetallic reaction.

e. The earth electrodes should be well packed with powdered

charcoal/mix upto the level of the connections.

f. The earth electrodes should be provided at a distance of atleast 3

metres apart from one another.

g. Double clamp arrangement with central through bolt for connecting the
earth leads should be provided. The double clamp should be fixed to
the main pipe. No reducer pipe shall be employed.

h. The clamps provided for the earth pipe should make full surface
contact with the earth pipe and the earth leads to ensure very low
contact resistance.

37
i. Each earth lead should be connected individually to the earth clamp.
Earth connections should always be visible for easy examination.

j. Each earth electrode should be identified permanently by engraving on

the inner side of the trough walls by wet cement with reference to earth
leads connected to it.

k. Periodic inspection and testing of earth electrodes should be carried

out in order to maintain the installation in a sound condition after
putting into service.

TYPICAL EARTH ELECTRODE

38
 CHAPTER - 4

EARTHING DESIGN

Designs related to the desired operating conditions and performance of

equipments are generally taken care due to compulsion since omission of such
aspects will result in to the mal-operation or equipment failure etc. which are not
be tolerated by the user. It can be seen practically that most of the faults like
system disturbance, equipment failure, fire etc. in a consumer installation are
attributable to an improper earthing.

However, earthing is the area where some of the installation engineers

tend to make either a thumb rule design or a redundant costly design without
estimating the actual requirement for a confidant design. Various parameters
related to earthing for evolving a reliable earthing design are therefore analysed
for a solid neutral earthing system in this chapter.

1. Purpose of Earthing

1.1 Earthing is done in an electrical installation to achieve the following

objectives:

i) Provide a low impedance earth fault return path to clear the earth
fault and to achieve protection.

ii) Limit the step and touch voltages on the accessible equipment
and surfaces both during normal operation and during transients
to safe levels.

iii) Minimise electrical noise interference in control and

instrumentation systems

iv) Minimise the effect of lightning strikes on personnel, equipment

and structures.

Hence, arriving at a safe value of earthing resistance is an essential

component to achieve the above objectives.

2. Providing low impedance earth return path

2.1 The purpose of providing earth electrodes with the related earthing
installation in a solid neutral earthing system for personal protection is to
offer an optimum value of earth resistance which is low enough to
produce a required earth fault current for an effective operation of
protective devices to clear the fault. Such devices could be relays in the
main breaker; HRC fuses or MCBs etc. in the distribution. Accordingly,
the value of earth resistance to be achieved should take into account of
the various configurations of system earthing.

39
3. Classification of systems based on Types of system earthing

3.1 Some of the generally practiced System Earthing Arrangement (SEA) are
furnished below:

a. TN - S System - A system which has one or more points of the

source of energy directly earthed and the exposed and extraneous
conductive parts of the installation are connected by means of
protective conductors to the earth points of the source thereby
ensuring a metallic path for earth faults to flow from the installation to
the earthed points of source.

b. TT System - A system which has one or more points of the source of

energy directly earthed and the exposed and extraneous conductive
parts of the installation are connected to a local earth electrodes or
electrodes electrically independent of the source earth(s).

c. IT System - A system which has source either unearthed or earthed

through a high impedance and the exposed conductive parts of the
installation are connected to electrically independent earth
electrodes.

3.2 As per BIS, the circuit diagram of the Indian TN - S system adopted at
the consumers’ premises is furnished below:

Fig.TN-S systems generally adopted in residential, commercial and

Public Assembly buildings
40
3.3 The TT and IT System of earthing are as per sketch furnished below:

Fig.TT and IT systems generally adopted in industrial premises and

power plants

3.4 It can be inferred from the above that the fault current returning to the
source would vary according to the type of earthing.

3.5 The following parameters are to be considered before selection of type of

earthing:

a. The required level of continuity of supply and operating conditions

b. The characteristic of the network , the type of loads and type of

premises

3.6 The following table may be referred for selecting the suitable type of
system of earthing:

41
 TABLE
EARTHING SCHEMES

Type of network Advised Possible Not

Very large network with high-quality earth TT,TN IT(1) advised
electrodes for exposed conductive parts (10Ω or mixed
max.)
Very large network with low-quality earth TN TN-S IT(1)
electrodes for exposed conductive parts TN-C
(>30Ω max.)
Distributed area(storms) TN TT IT(2)
(E.g. .television or radio transmitter)
Network with high leakage current (>500mA) TN(4) IT(4)
TT(3)(4)
Network with outdoor overhead lines TT(5) TN(5)(6) IT(6)
Emergency standby generator set IT TT TN(7)
Types of load
Load sensitive to high fault current(motor, IT TT TN(8)
etc.,)
Loads with a low insulation level (electric TN(9) TT(9) IT
furnaces ,welding machine, heating elements,
immersion heaters, equipment in large
kitchen)
Numerous phase – neutral single – phase TT(10) IT(10)
loads (mobile,semi,fixed portable) TN-S TN-C(10)
Loads with sizeable risk(hosts, conveyers, TN(11) TT(11) TT(11)
etc.,)
Numerous auxiliaries (machine tools) TN-S TN-C TT(12)
IT(12bis)
Miscellaneous
Supply via star-star connected power TT IT without IT(13)
transformer(13) neutral with
neutral
Premises with risk of fore IT(15) TN-S(15) TT(15) TN-C(14)
Increase in power level of LV utility TT(16)
subscription requiring a private substation
Installation with frequent modification TT(17) TN(18)
IT(16)
Installation where the continuity of earth TT(19) TN-S TN-C
circuits is uncertain (work sites, old IT(19)
installations)
Electronic equipment (computers, PLCs) TN-S TT TN-C
(20)
Machine control-monitoring network, PLC IT TN-S
sensors and actuators TT

42
(1) When the SEA is not imposed by regulation, it is selected according to the level of
operating characteristics (continuity of service that is mandatory for safety reasons or
desired to enhance productivity, etc.) whatever the SEA, the probability of an insulation
failure increases with the length of the network. It may be a good idea to break up the
network, which facilitates fault location and makes it possible to implement the system
advised above for each type of application.
(2) The risk of flashover on the surge limiter turns the isolated neutral into an earthed neutral.
These risks are high for regions with frequent thunder storms or installation supplied by
overhead lines. If the IT system is selected to ensure a higher level continuity of service,
the system designer must precisely calculate the tripping conditions for a sec fault.
(3) Risk of RCD nuisance tripping
(4) Whatever the SEA, the ideal solution is to isolate the disturbing section if it can be easily
identified.
(5) Risk of phase to earth faults affecting equipotentiality.
(6) Insulation is uncertain due to humidity and conducting dust. `
(7) The TN system is not advised due to the risk of damage to the generator in the case of an
internal fault. What is more, when generator sets supply safety equipment, the system
must not trip for the first fault
(8) The phase to earth current may be several times higher than I n, with the risk of damaging or
accelerating the ageing of motor windings, or of destroying magnetic circuits.
(9) To combine continuity of service and safety, it is necessary and highly advised, whatever
the SEA, to separate these loads from the rest of the installation (transformers with local
neutral connection)
(10) When load equipment quality is not a design priority, there is a risk that the insulation
resistance will fall rapidly. The TT system with RCD’s is best means to avoid problems
(11) The mobility of this type of load causes frequent faults (sliding contact for bonding of
exposed conductive parts) that must be countered. Whatever the SEA, it is advised to
supply these circuit using transformer with a local neutral connection
(12) Requires the use of transformer with a local TN system to avoid operating risk and
nuisance tripping at the first fault (TT) or a double fault (IT).
(12bis) With a double break in the control circuit
(13) Excessive limitation of the phase to neutral current due to the high value of the zero phase
impedance (at least 4 to 5 times the direct impedance). This system must be replaced by a
star delta arrangement
(14) The High fault currents make the TN system dangerous. The TN-C system is forbidden.
(15) Whatever the system the RCD must be set to ∆n  500mA
(16) An installation supplied with LV energy must use the TT system. Maintaining this SEA
means the least amount of modification on the existing network (no cables to be run, no
protections devices to be modified).
(17) Possible without highly competent maintenance personnnel
(18) This type of installation requires particular attention in maintaining safety. The absence of
preventive measure in the TN system means highly qualified personnel are required to
ensure safety over time.
(19) The risk of breaks in conductors (supply, protection) may cause the loss of equi-potentiality
for exposed conductive parts. A TT system or a TN-S system with 30mA RCD’s is advised
and is often mandatory. The IT system may be used in very specific cases.
(20) The solution avoids nuisance tripping for unexpected earth leakage

43
4. Design Criteria

4.1 In order to understand the principles of earthing and to arrive at a design,

basic ideas on the following associated factors should be taken in to
account.

 Fault level
 Current transformers, Relays & Protective gears
 Earth potential rise
 Soil resistivity
 Earth electrodes configuration
 Earth Resistance

4.2 Fault level consideration

4.2.1 Fault current, right from the point of supply up to various voltage levels
have to be ascertained for checking up the adequacy of earthing
conductor, proper selection of switchgears, fault clearing devices and
protection schemes for an effective earth fault clearance.

4.3 Current Transformers (CTs)

4.3.1 Current transformers (CTs) are used at the neutral earth flat in TT system
of earthing for sensing the earth fault current to trip the breaker. These
are protection class CTs which are expected:

a) to reduce the power system currents to values low enough for safe
sensing and operation of protective relays for actuating the fault
clearing devices like breaker in the secondary side of the
transformer feeding the down-stream installations.

b) to insulate the relay circuits from the primary circuit.

4.3.2 Performance and selection of CTs

a. Selection of CT, especially, at the neutral circuit for actuating the

earth fault relay to trip the secondary side breaker of the
transformer is an important factor in the earthing design. It is
governed by the sensitivity (minimum earth fault setting) and
highest instantaneous setting in % of primary current rating.

b. It can be seen that in low fault level a lower CT ratio will be

required in the neutral earthing current sensing arrangement
compared to the residual current sensing CT at the breaker where
the ratio is governed by OL setting.

c. In systems where the fault current is high and full load current is
low, it may be necessary to choose CTs with primary current
ratings related to the fault current rather than ratings related to full
load currents.

44
4.4 Relays & Protective Gears

4.4.1 Effective setting

a. In general, the neutral of the Star connected Secondary windings

of the Transformer is solidly earthed. As there is no impedance in
the neutral to limit the earth fault current, earth fault current due to
earth faults closer to the MV Panel will be considerably high, and
the relay coil may experience considerable heating during severe
earth fault. The lower the setting, the higher the resistance of the
relay coils. So the heating at lower setting tap is correspondingly
higher. So an earth fault setting of 40% is suitable for the majority
of applications and should be used unless it is known that service
conditions are such that lower settings are necessary.

b. The high-set element makes possible a reduction in the tripping

time at high fault levels and improves the overall system grading by
allowing the discriminating curves behind it to be lowered.

4.4.2 Relay Co-Ordination

a. The time interval between the operations of two adjacent relays

depends upon the fault current interrupting time of the circuit
breaker.

b. The circuit breaker must have completely interrupted the fault

current before the discriminating relay ceases to be energized.

4.5 Protective Gear

4.5.1 In order to clear the fault before it harms the person, protective gears are
employed in the power system. Protective gear is a collective term which
covers all the equipment used for detecting, locating and initiating the
removal of a fault. A typical combination is the current transformer, earth
fault relay and circuit breaker. Direct acting MCCBs, MCBs, ELCBs,
HRC fuses are also protective gears.

4.5.2 In the case of relying protective devices like MCCB, MCB, HRC fuse etc.
for the protection of downstream feeders and loads for earth fault
protection, it should be ensured that the value of earth fault loop
impedance is achieved in such a way that required earth fault current is
achieved.

4.5.3 It should always be ensured that the (I2 t) let through energy of the
protective gear is matched and is always less than that of the protected
circuit’s permissible let through energy.

45
4.6 Earth Potential Rise (EPR)

4.6.1 The maximum electrical potential that a substation earthing grid may
attain relative to a distant earthing point assumed to be at the potential of
remote earth. This voltage, EPR, is equal to the maximum grid current
times the grid resistance.

NOTE:
Under normal conditions, the grounded electrical equipment operates at
near zero ground potential. That is, the potential of a grounded neutral
conductor is nearly identical to the potential of remote earth. During a
ground fault the portion of fault current that is conducted by a substation
earthing grid into the earth causes the rise of the grid potential with
respect to remote earth.

4.6.2 Safe let-through current and Touch potential

a. A person can withstand without ventricular fibrillation, the passage of

a current in magnitude and duration determined by the formula: I
b=0.116/√t; where Ib is the fibrillating current in Amps, t is the

duration of current flow in seconds. Based on this expression and

normal body resistance, the safe touch potential is expressed as:

E TOUCH (in volts) = I b*1000

b. This EPR has to be contained to acceptable levels as per table given

below:

Table

E touch voltage
518 366 259 164 116 82 67
in volts (EPR)

t in seconds 0.05 0.1 0.2 0.5 1 2 3

c. The safe touch potential of 67V for 3 seconds can be taken into
account for avoiding nuisance tripping of whole plant due to down
stream faults, for enabling co-ordination with the down stream
protective devices and for achieving discrimination. It can be done
by suitably setting the TDS of the earth fault relay to actuate the
secondary side breaker of the transformer. Hence, the operating
principles of the fault clearing devices and fault level are to be
considered before proceeding further.

d. In the case of relying over current protective devices (like MCCB,

MCB.HRC fuses etc. for down stream loads at distribution panel
boards) for earth fault protection, value of earth resistance and the
46
 time current characteristics of the devices should be matched to
offer fault clearance for the EPR within the time duration furnished in
the above table. Hence it becomes essential to opt for ELCB, EF
relay, CBCT actuated devices at such conditions.

4.7 Soil Resistivity

4.7.1 Since earth plays a vital role in the earth fault circuit, it is essential to
know its characteristics, particularly, the soil resistivity.

4.7.2 Ascertaining soil resistivity of the installation forms the initial part of the
design. The following Table, based on the field tests using four terminal
earth tester shows the variation of soil resistivity for different types of soil
and the influence over the corrosion. Average soil resistivity may be
taken if the deviation observed between various readings is not more
than 30%. Otherwise separate soil strata have to be considered for
arriving at the value of the respective earth electrodes.

4.7.3 Since the earth resistance value obtained by the combination of various
earth electrodes is greatly influenced by the soil resistivity, the quantity of
such electrodes required is also dependant on the soil resistivity.

Table

Soil Resistivity and Typical values

ρ = 2*22/7*s*R Ohm-Metre
where ρ = Soil Resistivity

Typical values

(s) Distance Effect of corrosion on the

( R ) Resistance
between (ρ ) Soil range of soil resistivity
in Ohms (as
successive Resistivity in
measured by
earth spikes in Ohm-Metres Soil resistivity Effect of
the instrument)
metres in Ohm-metre corrosion
5 0.5 15.715
5 1 31.43 -- --
5 2 62.86
5 3 94.29 upto 25 Severely
corrosive
5 4 125.72 upto 50 Moderately
corrosive
5 5 157.15 upto 100 Mildly
corrosive
5 7 220.01 above 101 Very mildly
corrosive

47
4.8 Earth Resistance

4.8.1 The earthing resistance of an electrode is made up of:

a. resistance of the (metal) electrode,

b. contact resistance between the electrode and the soil, and
c. resistance of the soil from the electrode surface outward in the,
geometry set up for the flow of current outward from the electrode to
infinite earth;

4.8.2 The first two factors are very small fractions of an ohm and can be
neglected for all practical purposes. The soil resistivity is an important
factor which determines the resistance to earth.

4.9 Earth electrodes configuration

4.9.1 The shape of earth electrodes is dictated by the site conditions and
especially the earth resistivity.

4.9.2 Pipe electrodes

a. Resistance of Pipe or Rod Electrode

100 x ρ x [log e (4L/d)] Ohms

R =
2 x3.14x L

where ρ = Soil Resistivity in Ohm-m

L= Length of Pipe or Rod in cm
d= Diameter of Pipe in cm
R= Resistance of Earth Electrode in Ohms

b. The following table shows the values of earth resistance for the
widely used pipe or rod electrodes:

Typical Values

Soil Length of Pipe Diameter of Resistance of Earth

Resistivity in or Rod in cm Pipe in cm Electrode in Ohms
Ohm-M (ρ) (L) (d) (R)
10 300 3.8 2.522646045
50 300 3.8 12.61323022
100 300 3.8 25.22646045
500 300 3.8 126.1323022
1000 300 3.8 252.2646045

48
c. Multiple Earth electrodes

i. Multiple electrodes in parallel yield lower resistance to ground than a

single electrode. An useful rule is that earthing systems of 2-24 rods
placed one length rod apart in a line, will provide a earthing
resistance divided by the number of rods and then multiplied by the
factor ‘F’ taken from the following table. Placing additional rods within
the periphery of a square, circle etc. will not appreciably reduce the
earth resistance below that of the peripheral rods alone.

ii. Multiplying Factors for Multiple Rods (F)

Number of rods 2 3 4 8 12 16 20 24
Multiplying Factor (F) 1.16 1.29 1.36 1.68 1.8 1.92 2 2.16

4.9.3 Strip Electrodes

Where
(R) is the Resistance of Earth Electrode in Ohms
100 * ρ * [loge (2l2/wt)] (l) Length of Strip or Rod in cm
R = Ohms (w) Depth of Burial of Electrode in cm
2 * 3.14 * l (t) Width(For Strip) or Twice The Dia (For
Conductors) in cm
ρ = soil resistivity in ohm-m

Typical Values

Width (for
Soil Depth of Strip) or
Length of (R) Resistance of
Resistivity Burial of Twice the dia
Strip or Rod Earth Electrode in
in Ohm-m Electrode in (for
in cm (l) Ohms
(ρ) cm (W) Conductors)
in cm (T)
10 1000 50 6 1.4013394
20 1000 50 6 2.802688
25 1000 50 6 3.503386
50 500 50 6 11.80738
75 1000 50 6 10.51046
100 1000 75 6 13.36876
100 500 50 6 23.614
100 1500 50 6 10.203
100 2000 50 6 8.1099
100 3000 50 6 5.8368
100 1000 50 6 14.013

49
 Note:
1) Depth of burial should not be less than 50 cm below earth
2) More than 60 m length of strip does not yield improvement in earth
resistance value

4.9.4 The combination of pipe and strip electrodes forming the combined earth
resistance can be ascertained from the above tables and the number
pipe or strip electrodes required can be ascertained.

4.9.5 Typical Plate Electrode

4.10 Adequacy of earthing conductors and earth electrodes

4.10.1 It goes without saying that the earthing conductor as well as the
electrodes should meet a variety of design factors like withstanding short
time and long time over loading of earth electrodes, dissipating the
temperature rise attained during fault conditions without igniting the
surrounding materials, without fusing out by itself etc. and more
importantly to restrict the let-through current suffered by the personal
during the fault conditions within the permissible limits. Tables furnished
below illustrates the above factors depending upon the site conditions for
designing:

Size of earth flats If * Sq Root (t)

Where t=3seconds
‘S’ in Sq.mm = K

50
 Where If is fault current in ampere
t is operating time of the disconnecting, device in seconds
S is cross sectional area, in square milli-metres.
k is factor dependent on the material of the protective
conductor, the insulation and other parts, and the initial and
final temperature.
Values of k for protective conductors in various use or service are
given in the following Tables:

Table
Values of k factor for calculating the area of cross section of various type of
earthing conductors for a fault clearing time of 3 seconds
A. Bare conductor with no risk of fire or danger to any other touching or
surrounding material
Initial Final
Copper Aluminium Steel
temperature temperature
40 395 118
40 325 73
40 500 46
B. Insulated protective conductors not incorporated in cables
or Bare conductors touching other insulating cables
Initial Final
Copper Aluminium Steel
temperature temperature
40 160 79 52 2 8 PVC
40 220 92 61 3 3 Butyl
rubber
40 250 98 65 3 6 XLPE/
EPR
C. Protective conductor as a core in multicore cables
70 16 66 44 P V C
85 22 77 51 Butyl
rubber
90 25 83 54 XLPE/
EPR
D. Protective bare conductors in hazardous areas where there is risk of
fire from petroleum bound oil or other surrounding material
Initial Final
Copper Aluminium Steel
temperature temperature
40 150 76 50 27
40 200 88 58 32

51
 Typical values
Fault current (t) Operating (k) Constant for various Area of cross-
flowing time of the type of materials used as section of the
through the disconnectin earthing conductors (for earth conductor in
protective g device in 1 to 3 sec operating Sq.mm
device in seconds time)
Amps
Copper steel (for 3 For copper
(for 3 sec) sec)
2500 3 118 46 36.695992
10000 3 118 46 146.78397
20000 3 118 46 293.56793
21350 3 118 46 313.38377

4.11 Current density of the earth electrode

4.11.1 The earth electrode should be capable of dissipating with out failure the
energy in the earth path at the point at which it is installed under any
condition of operation on the system.

The maximum permissible current density (Id) given by:

Current density for earth electrodes Id

Id for protective gear = 1140xd / (sqrt(ρxt)) = Amps/metre

of length of earth rod

where t = duration of earth fault (in second)

ρ = resistivity of the soil (in Ω. cm)

d = Rod Diameter in mm

4.11.2 In order to avoid an increased earth resistance value as well as heat

generation during the earth faults, the minimum number of earth
electrodes required should also be designed on the following basis:

If
Total Area of earth electrodes required (A) = Sq.mm
Id

where If = Fault current and Id= Current density

52
 The actual number of earth electrodes required would be based on the
following formula:

where 'a' is the area per electrode

(for two sides of plate earth
Number of electrodes required to electrode).This formula holds
prevent earth electrodes from the = A/a good for plate earth electrodes.
current loading effect However, the allowable current
density can be verified for long
duration loading.

4.12 Typical approach for arriving at the required earthing design in TT

system

Based on the design factors enumerated above and the above concepts,
the earthing design required for an installation can be worked out as
follows:

Step – 1

Compute the fault level upto the consumer’s premises

a) Ascertain the fault level (MVA) of the utility (TNEB) substation which
feeds the consumer’s installation. Calculate the source impedance
for this fault MVA.

b) Know the rating, voltage and percentage impedance of the

transformers at the above substation. Then find the impedance for
these transformers.

c) Add the impedance found in ‘a’ and ‘b’ above. Then convert it to the
secondary side voltage of substation.

d) Get the details of distribution lines/cables i.e. type of conductor /

cable, length and hence the value of R and X L. Calculate Z of the
lines / cable upto the consumer’s point of commencement of supply
at the consumer installation.

e) Find the impedance of consumer’s transformer. Add the impedances

‘c’ and ‘d’ to know the impedance upto the consumer’s premises at
the point of supply.

f) Convert the impedance in ‘e’ above to the secondary side of the

consumer’s transformer.

53
 g) Find the impedance of the secondary circuit cables / bus bars. Add
‘e’ and ‘f’ to arrive at the total impedance upto the incomer of main
panel provided at the secondary side of the transformer.

h) Calculate the fault current from the impedance ‘g’ above. A minimum
fault level of 13.1KA has to be considered, if the value arrived under
item ‘g’ above is less than 13.1KA.

Step-2

Selection of CT at the neutral earth flat circuit

a) Select a CT based on the fault level in such a way that it is not

saturated. Preferred CT connection is, providing the CT at the
neutral earth flat. The minimum relay setting determines the minimum
earth fault current for which the CT can feed for the relay operation.

40% is a nominal value for electromechanical relays and it can be

reduced to 10% in the case of static relays.

If the earth fault current sensed by the CT is decreased, the

permissible earth resistance can be of higher value. Hence CT
selection, relay setting and safe let through current are the factors
which determine the safe duration of persistence of earth potential
rise.

A safe time interval of three seconds can be taken into account for
affording a safe margin of successive protective gears’ operating
time.

However, a reduced time interval can also be considered for specific

situations. Here care shall be taken to avoid the main breaker
responding to a fault of the down stream switch gear panel.

b) The earth resistance value has to be calculated based on the

permissible touch voltage and the operating time (fault clearing time)
of the protective gear from the inception of fault.

Step-3

Soil resistivity and combined earth resistance value

The earth resistivity of the soil has to be ascertained. Depending upon

the soil resistivity and the physical location of earth pipe / rod and strips,
the number of pipes and various lengths of strips can be arrived at by trial
and error method in a simple excel work sheet programme. The

54
 combined value of the different earth electrodes has to be arrived at to a
value less than that determined in step II.

Step – 4

Size of earth flats

Based on the fault current, time of operation of the fault clearing device,
material, type of material used for the earth connection and corrosion for
the soil, the size of earth flat has to be found. This minimum size should
be ensured for the neutral of the transformer and for the interconnection
from transformer and for the interconnection from the transformer to its
secondary side panel board.

Step – 5

Current loading capability

Satisfying conditions for short time and long time current loading capacity
of the overall earthing conductor constituted by the combination of pipe
and strip earthing conductors should be ensured.

Once the above calculation is made, one can confidently assure the
earthing design for the specific installation.

4.13 Unfavourable conditions

When the design could not yield a favorable condition and a difficulty is
encountered in bringing down the earth resistance value to the required level then
there lies a possibility of danger from the transferred potential when the source
neutral earthing attains potential above the normal earth potential.
In the above cases and locations like bath room, garage, polishing
section at granite industries etc., it is difficult to ensure personnel as well as
equipment protection unless the following measures are adopted like use of:
a) RCB at the source end,
b) Isolation transformer with separate earthing for such derived
source of supply,
c) Having the incomer rating of the DBs restricted to the earth fault
clearing current restricted by the earth loop impedance values,
for such portion of the installation.

55
4.14 Earth Leakage Circuit Breaker

ELCBs are devices that sense when current—even a small amount—

passes to earth through any path other than the phase conductor. When this
condition exists, the ELCB quickly opens the circuit, stopping all current flow to
the circuit and to a person receiving the earth-fault shock.

The following figure shows a typical circuit arrangement of an ELCB

designed to protect personnel.

A fuse or circuit breaker cannot provide this kind of protection. The fuse
or circuit breaker will trip or open the circuit only if a line-to-line or line-to-earth
fault occurs that is greater than the circuit protection device rating. ELCB-
protected circuits is one way of providing protection of personnel using electric
hand tools at construction sites, damp locations, individual houses etc.

However an ELCB will not protect the user from line-to-line or line-to-
neutral contact hazards. If the employee drills into an energized conductor and
contacts the metal chuck or drill bit, the ELCB device will not trip (unless it is the
circuit the ELCB device is connected to) as it will not detect a current imbalance.

56
4.15 Earthing of computers and sensitive equipments

Supply for the computers and sensitive installations are generally derived
from the main source using isolation transformer and UPS in order to avoid
surges. In such cases, earthing should be done as per sketch shown below so as
to minimise the neutral to ground potential within limits.

57
 CHAPTER - 5

SWITCHGEAR & POWER DISTRIBUTION

1 General

Power Distribution to loads should be effected using sub switch boards,

distribution boards, motor control centre, over head bus bar trunking,
vertical rising mains or any of these combinations.

2 Switch Board

2.1 Clearances

1. The H.V. Switch Board/ M.V. Switch Board, control panel of the
generator should be erected with the following clearance measured
from the farthest point:

a. Front One metre

clearance

b. Rear i. Minimum 750 mm if there are termination on

clearance the rear side with a necessity to work (or)
ii. Less than 200 mm if there is no entry of cables

c. Side If the rear clearance is 750 mm and above, a

clearance minimum clearance of atleast 750 mm should also
be provided on both side of the board.

2. Where the rear clearance is 750 mm or more, a passage way clear to

a height of 1.8 m should be provided.

3. If two switch boards are erected adjacent to each other in the same
line, the clearance between the two switch boards should be either
less than 20 cms or more than 75 cms.

4. H .V or M.V. Circuit breaker, if erected independently should have to

be erected with a clearance of not less than one metre on the front
side and a clearance of not less than 750 mm on either sides.

58
 5. The following creepage clearances shall be observed in the switch
board:

Phase to earthed
System Voltage Phase to Phase
metal clearance
(kV) clearance (mm)
(mm)
0.416 19 16
0.6 25 19
3.3 51 35
6.6 77 60
11 127 77
22 242 140
33 356 223

4.3 Construction and arrangement

4.3.1 Switch boards

1. Compartmentalization of different components, namely, cable

chamber, bus chamber and feeder control chambers is an
essential element to be observed in order to limit fire propagation
between various chambers during the manufacture of the switch
boards.

2. Further, the basic requirements relating to the fulfilment of meeting

the nominal as well as fault requirements and co-ordination for
discriminative protection in respect of the different components like
bus bars, incoming and outgoing feeder controls, safe working on
individual feeder etc should be observed in the manufacturing
stage itself.

3. Switchgear room should be well ventilated and easily accessible.

The room should be adequately illuminated so that the switchgear
should be easily identified and operated comfortably.

4. The switchgear room should not be used as store room and

materials unrelated to switchgear should not find a place therein.
Tidiness is very essential.

5. Erection of switch board below the stair case should be avoided.

However, if the switch boards are to be erected below staircase, a
minimum head room clearance of 1.8 m should be ensured.

6. Double approach way should be provided for SSB’s erected in

elevated platforms with a suitable ladder/ step arrangement
59
7. The storage batteries meant to provide D.C. Supply for control
circuits of switchgears should be erected in the switchgear room,
housed in leak proof enclosures. Where the capacity of Storage
batteries is quite large and considerable these should be installed
in a separate room to prevent circulation of fumes in the switchgear
room.

8. Switch boards should be away from corrosive fumes, dust and

excessive heat. To ensure safety and long life of the switchgears in
factories, where dust and fumes are present, glass panelled
housing should be provided. The surrounding of the sub-switch
board should be clean and tidy. Where products and raw materials
are likely to be dumped and at car parking area, the sub-switch
board and cabling there from should be protected by suitable
barriers.

9. Milli volt drop test should be conducted at the joints of buses to

ensure proper contacts of various joints.

10. Door interlock should be provided for each switch Fuse/ breaker to
ensure opening of the front door only when it is in OFF position.

11. The incoming and outgoing cables from SSB’s should be either in
over head cable trays or cable trenches with ladder arrangement.

12. In double fronted switch boards tap off points at main bus bars
should be taken from its respective sides. Criss cross tapping
should be avoided.

13. The live main bus bars and outgoing control chambers should be
segregated using sheet metal work.

14. Each vertical compartment should be segregated from the

adjoining cable/ switch compartment.

15. The live incoming terminal at the main incoming switch control
should be covered using non-inflammable materials.

16. In case of interlocked fuse switches/ circuit breakers/ bus-coupler

receiving two sources of supply, both the incoming terminals
should be covered and segregated from each other.

17. The interconnections between the bus bars and the switch fuses
and fuse switches of more than 63 Amps rating should be of rigid
conductors.

18. Adequate rating of nearby control should be provided for machines

fed from BBT’s with plug in and controls located at a height of more
than 1.8 metre.
60
19. The Ammeter, Voltmeter indicating lamps, Control circuit fuses
etc., should not be mounted on the face of the bus bar chamber.
Hinged cover should not be provided for the front side of the bus
bar chamber of the Switch Board. When instrument like Ammeter,
Voltmeter are mounted on the door, the earth wire should be
extended to the door.

20. The draw out circuit breaker should be provided with automatic
shutters to cover the live terminals when the breaker is in drawn-
out position.

21. The control should be mounted at an accessible height and shall

be ensured that operations are done without opening the front
cover of such control chamber.

22. Each switch chamber shall incorporate only one switch control.

23. The terminals of each outgoing feeder should be completely

segregated inside cable chamber so that it is possible to safely
work on individuals terminals without switching OFF other feeders.
Further bus bars from the controls should not protrude at the cable
termination so that the outgoing cables are terminated directly at
the controls within the control chamber.

24. The bus bars including the interconnections between the bus bars
and the incoming side of the switch control should be made
inaccessible when the doors of the controls are opened.

25. No direct tapping from the bus bar should be made for any feeder
without control and protection. Each outgoing circuit from switch
board should be separately controlled by a linked switch fuse/
switch or circuit breaker of adequate capacity.

26. The cable chamber should be of sufficient size to accommodate

the required number of cables so as to avoid any strain on cable.

27. Incoming and outgoing cable should be segregated and in the case
of HT gears the incoming and outgoing cable should be terminated
in separate chambers.

28. HRC Fuse/ MCCB settings provided in the circuit shall

commensurate with the connected load.

29. Rubber mat conforming to IS 15652 should be provided in front of

all Switch Boards for their entire length.

30. Sufficient number of electrically tested rubber gloves should be

made available in Main Switchgear room. These rubber gloves

61
 should be kept in suitable teak wood box dusted freely with chalk
powder.

31. A shock treatment instructions card should be kept framed in Main

switchgear room. The name and address together with telephone
number of any of the nearest doctor should be entered in it.

32. First aid box containing full compliments of ointments and

medicines for treatment of electrical burns should be provided with
telephone number of any of the nearest doctor should be entered
in it.

33. Adequate number of fire-extinguishers of suitable sizes suitable for

dealing with electrical fire (DCP/CO2 ) should be provided inside or
near the Switchgear room so as to be readily available for fire
fighting.

34. Suitable fuse pullers should be made available in switchgear room

for easy and safe renewal of flange type HRC fuses.

35. Suitable operating rod should be provided for operating drop-out

fuses, if D.O. fuses are provided in the Sub-station.

36. Suitable discharge rod should be made available in the Switchgear

room to facilitate earthing of the lines / cables before attending to
works.

37. A list of authorized persons in proper form duly signed by the

person authorizing the works and persons authorized should be
kept in Main switchgear room.

4.3.2 Bus duct / Bus bar Trunking (BBT)

1. When loads are formed in a row, overhead bus bar trunking should
be employed to suit the convenience and reduction in distribution
cost. In such cases, the following should be observed.

2. A breaker of adequate rating should be provided to control the

supply to the BBT and such control should be capable of being
operated conveniently.

3. Over head BBT can feed power DB’s for further distribution

4. The unused opening of the plug-in-boxes in the BBT should be

blocked

5. All plug-in-boxes should be identified with reference to the machine/

equipment connected to.

62
 6. Cables from BBT tap OFF box to machines should be properly
supported.

7. The ends of aluminium foils forming the flexible expansion joints at

the bus duct etc. should be formed as a solid mass using inert gas
welding for minimising contact resistance at the joints.

8. Bus duct / Bus bar should be designed taking into account the
derating factors due to Conductivity of materials used, Skin Effect &
Proximity effect, Painting of bus bars, Altitude above mean sea level
etc. and adequacy of the following Electrical & Mechanical
parameters should be verified:

i. Cross section Area of bus bar to withstand Temperature Rise

under normal conditions and short circuit.

ii. With standing of Busbar & supports due to Dynamic force

developed during short circuit.

9. Diagram of Typical Bus Duct:

4.3.3 Distribution Boards

1. The following should be complied with in the case of MCB and HRC
fuse DBs:

i. The supply to individual MCBs (SP MCBs) meant for controlling

final circuit should not be effected by way of looping using short
bit of wires. Bus bars or E-connectors of adequate size and
length should be provided for availing supply to phase and
neutral circuit of the SP MCB controls.

ii. The live bus bars, live outgoing terminals and live tappings
should be covered by insulating sleeves/ materials to avoid
accidental contact.

iii. The type and rating of MCB or HRC fuse should be selected
based on the fault level at the point of application, starting

63
 current and rating of load connected to the MCB or HRC fuse
control.

iv. The MCB or HRC fuse controls in the MCB DBs should be same
rating and pole configuration of MCB’s should be same.

v. Dummy fuse carriers should be provided for the spare ways in

the HRC fuse distribution board so as to cover the exposed live
parts.

vi. Rewirable fuses should be not used in DB’s designed for HRC
fuses.

vii. All unused knock-out holes in MCB DBs/HRC fuse distribution

boards should be covered by non-inflammable material.

viii. The opening between the incoming Switch Control and HRC
fuse distribution fuse board should be covered by suitable
insulating sheets.

2. The incomer control of the MCB DBs feeding final circuits should be
of TP type only instead of 4 Pole in order to avoid raise in the phase
voltage at the single phase loads and final lighting circuits due to
poor contact or disconnection of neutral circuit. Further, DP MCB
control should be provided for the outgoing single phase loads and
final lighting circuits in such DBs.

3. DP MCB control should be provided on the incoming side of the

MCB DBs feeding the single phase loads and final lighting circuit.
Each outgoing circuit of such DBs should be controlled through a
separate SP MCB.

4. Distribution boards should be of proper construction for ingress of

protection depending on the environmental condition.

5. DB’s should be erected at convenient height so that top row of fuses

are accessible without the aid of stool, platform etc and easily
approachable.

6. MCB DBs/HRC fuse DBs should be identified and provided with

circuit lists.

7. The Distribution Board should be minimum of 4 ways and maximum

of 12 ways and should not be of odd number ways. The rating
should be limited to a maximum of 63 Amps per way.

8. Fuse should never be provided in the neutral circuit. Link alone

should be provided in the neutral circuit for testing purpose.

64
 9. T-joints and looping of conductors should never be adopted.
Standard distribution arrangement should be adopted. Supply to the
motors should not be tapped from open wires run on buildings, walls
or ceiling. Standard distribution arrangement should be provided.
Unarmoured cables and wires should not be run in trenches and
cable racks from switch boards/ DB’s to motors or equipments and
such supply leads should be enclosed in conduits.

10. Distribution board should not feed another DB.

11. The outgoing and incoming cable should only be connected at the
bottom or at the top of the DB’s and not at the rear, side and front. If
sufficient space is not available to connect all these cables to the top
or bottom of the DB, an adopter box of adequate size should be
employed.

4.3.4 Controls

1. The Sub-switch boards/distribution fuse boards/ MCB DB should

be provided with adequate means of control of type 2 coordination
or by switch fuse on the incoming side, near the boards. However,
such control can be dispensed with if the boards are erected within
about 3 metres from the switch board feeding it and are in the
same room.

2. Each outgoing circuit from the sub-switch boards should be

provided with a switch fuse / fuse switch /MCCB only.

3. The current causing effective operation of the protective device

(fuse or breakers) should not exceed 1.45 times the current
carrying capacity of the down-stream cable.

4. Rotary switches should be used for controlling the control supply

only.

4.3.5 Cables

1. Cable of appropriate grade of insulation should be employed

depending upon the design and need.

2. The size of the cable should be selected with due consideration for
the drop in voltage, method of laying the cables, the load current,
short circuit current at the point of application and grouping factor
for multiple cables.

3. The size of the cable used for connecting the motors should be
capable of carrying the full load current as well as the starting
current.

65
4. H.V. & M.V. cables should not be laid in the same trench. If it is
unavoidable, suitable segregation should be provided.

5. Armoured cable alone can be laid directly in ground, in open areas

or in built-in trenches or ducts or trays in the factories. If
unarmoured cables are used, these should be enclosed in suitable
earthed mechanically strong metal casing.

6. The depth of laying the cable under the ground should generally be
as recommended by the manufacturer of the cable

7. Sharp bends should be avoided and bends must be long and

smooth. The manufacturers’ recommendations in this regard
should be strictly adhered to.

8. Where road/cable crossings are unavoidable, it is advisable to take

the cable in ducts/steel pipes/concrete pipes or hume pipes. It is
advisable to provide spare pipes for future cables

9. The cable should not pass through storm water drain, drainage
trenches and should not be taken along the side of water mains.

10. Cables trenches should be filled with sand, pebbles and should be
completely covered with non-inflammable slabs.

11. Cables can also be taken along columns, trusses side walls with
suitable support clamps inside buildings.

12. Cables can also be taken in mild steel/Aluminium/G.I. Ladder type

or perforated cable trays suitably fixed to truss or column of
walls/ceiling.

13. Extra length of the cable in the form of a loop should have to be
provided at both ends to facilitate jointing in case of joint failure.

14. The advice of the cable manufacturers with regard to installation

jointing and sealing should have to be followed and an
experienced cable jointer must be utilized for carrying out the job.

15. Permanent cable route indicators should be provided and location

of joints in the cable identified.

16. Smoke detectors shall be provided in the cable cellar room/ above
the cable tray and connected to fire alarm circuit as per standards.

66
17. Sketch showing typical arrangement of cable trench and cable cellar

18. Sketch showing the Method of HT UG Cable laying

67
4.3.6 Circuit Wiring

1. Suitable cable glands should be provided at all terminations.

2. The conduits should be supported by using clamps. It should not be

laid underground.

3. PVC bushes should be provided at conduit ends to prevent damage

to the installation of the wires by sharp edges.

4. Lugs should be provided for terminating the multi-stranded

conductors.

5. Equipments receiving supply from one DB/Sub-switch boards as far

as possible be grouped together so that the supply cables do not
mix/cross those from other distribution boards.

6. Supply to the portable/transportable equipments should be effected

by means of plug & socket outlet arrangement with heavily insulated
and adequately protected cable like TRS cable etc.

7. ELCB of 30 mA leakage current sensitivity should be provided in the

incomer of DB’s or socket outlets feeding the portable equipments.

8. The flexible conduit should normally be avoided, but in the case of

equipment, which require adjustments like motors used for belt
drives, motors in vertical drill etc. flexible conduit should be used to
the required minimum length only.

9. Heavily insulated flexible cables alone should be used for the holder
as well as the return circuits for the welding sets.

10. The electric distribution network should be distinguished from the rest
like telephone wiring, water, gas or air pipes etc.

4.3.7 Equipment Installation

1. The switch gear for the individual equipment should be rated for its
full rated current.

2. In explosive and hazardous areas, flame proof type switchgears are

to be used.

3. No socket outlets, electric motors, heaters, portable lights or other

portable electric equipment should be located in fire hazard godowns.

4. Built-in switches of the equipment can be used based on actual site

locality, accessibility etc. If so, it should be ensured that the incoming
terminal of these isolators are properly shrouded so that there is no

68
 likelihood of accidental contact while working in the control panel of
the equipment after switching off the isolator.

5. In the case of single machine comprising more than one motor or

equipment, suitable terminal block should be provided after the main
isolator of the machine to take individual circuit connection to each
motor or equipment of the machine. The control panel, should have
suitable fuses for individual motors.

6. If neutral is not brought to the equipment and any single phase circuit
is taken for lamp etc. suitable step down transformer should be
installed for the single phase supply.

7. Wooden base should not be used for mounting the motors, starters,
switches and apparatus.

8. Motors installed outdoor should be erected in weather proof

enclosure to withstand sun and rain.

9. Industrial heating lamps (infra-Red lamps and the like) should be

connected to the power distribution only.

10. The number of power socket outlets in final sub-circuits should not
exceed four in single phase and two in three phase.

11. Single phase outgoing from a three phase switch board should be
avoided.

12. Each power socket outlet should be provided with suitable control
near it. It is preferable to use an interlocked switch socket outlet in
order to remove the plug only in OFF position.

13. For single phase power equipment, connected through plug and
socket, fed from TPN distribution board, it should be ensured that a
switch is provided on the phase line.

14. Danger notice should be provided for the transformer/generator/

switchboards/distribution boards/motors/electrical equipments etc. in
a conspicuous position

15. Isolation transformer and voltage stabilizer should be provided for the
supply circuit to the computers to avoid voltage spikes and surges
which are harmful to the computers and other sensitive electronic
equipments.

4.3.8 EOT Crane

1. The switch to cut-off supply to the E.O.T. Cranes should be installed

at an accessible height.

69
 2. Necessary guarding should be provided for the overhead bare
copper conductors (down shop leads) employed for the E.O.T. Crane

3. Sufficient clearance should be provided for the live conductors.

4. Adequate ground clearance should be provided for the bare

conductors (down shop leads) from floor level.

5. Where system neutral is not taken for the overhead travelling crane,
the lighting circuit, if any, in the E.O.T. crane should be taken from a
separate suitable transformer

6. Suitable Pilot lamps should be provided at both ends to indicate that

the down shop leads are alive.

7. The supply to the trolley wire should be given at the end. In case
supply is given in sections, it should be ensured that the joint is
brazed and made heavy, as not to interfere with a collector pulley.

8. For the cranes moving on rails, all the rails to be earthed and
interconnected.

4.3.9 Installation of Capacitors

1. Power Capacitors are used for improvement of Power Factor for

reducing the reactive current thereby reducing the Power bill.

2. Suitable provision should be made for immediate and automatic

discharge of every static condenser or capacitor on disconnection of
supply.

3. Where the Capacitor is connected, across the terminals of the

motors, suitable terminal connector should be provided at the motor
terminals to avoid looping connection.

4. When the capacitor panel is built within the main panel, the size of
the bus bar should be of adequate size. Also adequate individual
control should be provided for the capacitor bank.

5. The control gear and size of cable for the Capacitor should be
adequate for the duty and the manufacturers’ recommendations
should be strictly adhered to while designing the size of the cable and
rating of control gear, taking into account the derating factor involved.

6. Linked switch-fuse of adequate rating should be provided to control

and protect the circuit to the Capacitors. Where capacity of banks is
100 kVAr and above it is desirable that a circuit breaker of adequate
capacity is provided.

70
4.3.10 Lightning and Surge Protection Devices (SPD)

1. In order to avoid pre-mature failure of sensitive electronic

equipments like Computers, servers, UPS, Soft starter, PLC, CNC
machines, CCTV, communication devices etc., protection from
conducted & radiated surges are required.

2. Radiated surges (in the form of LEMP- Lightning Electro Magnetic

Pulses) are greatly reduced by the use of Faraday cage type of
External lightning protection system in the form of Air terminal,
Down Conductors & Ring Earthing as per guide lines furnished
below:

 Type 1 LPS (Lightning Protection System) is needed for

Major Hospitals having more than 1000 beds & I.T.
companies having large amount of PCs & servers.
 Type 2 LPS is needed for Petrochemical plants, refineries &
Fertilizer plants.
 Type 3 LPS is needed for Cement plants, power plants- i.e.
all types of industries other than the above.
 Type 4 LPS is needed for Independent villas, multistory
apartments etc.

3. Conducted surges are reduced to great extent by the installation of

Surge Protection Devices (SPDs) at the following entry points:

 At the Main DB - Min. 25 kA (10/350 micro Seconds) SPD

between each phase to neutral & Min. 50 kA SPD (10/350
micro Seconds) from Neutral to Earth.

 At the sub DB -

Phase to Neutral: Min of 5 kA (10/350 micro Seconds) of

lightning surge & 50 kA (8/20 micro seconds) of Maximum
Surge current.

Neutral to Earth: Min of 25 kA (10/350 micro Seconds) of

lightning surge & 50 kA (8/20 microseconds) of Maximum
Surge current.

 At the equipment level -

Phase to Neutral: Min 30 kA (8/20 micro seconds) of

Maximum Surge current.

Neutral to Earth: Min 40 kA (8/20 microseconds) of Maximum

Surge current.

71
4. Power line SPDs are connected in parallel to the load whereas the
Data/Instrumentation line SPDs are connected in series. Parallel
connected SPDs need local & remote indication facilities for failure
indication & should be plug in type for easy replacement.

5. Apart from the above, data line SPDs are needed depending upon
the sensitivity of the equipment- i.e Server, routers, CCTV cameras,
TV, RS 485 communication etc. For detailed & accurate
determination of LPS & SPDs, Risk Assessment as per IEC 62305-2
has to be carried out.

72
 CHAPTER - 6

GENERATORS

1. The generator should be erected in a well ventilated room with the

radiator of the engine facing the opening for effective heat radiation.

2. The exhaust pipeline system should be provided to fulfill the Pollution

Control Board Norms.

3. The generator should be as close to the main change-over board as

possible. In cases like textile mills where there is a possibility of smoke
affecting the quality of the yarn etc, generators may be located away from
the plant/ department.

4. No oil drums and other containers should be stored in the generator room
and the room should not be used for any extraneous purposes, nor any
equipment pertaining to other services installed therein.

5. Danger Notice indicating the working voltage should be affixed in the

generator enclosure and control panel. The batteries should be placed
over an acid proof metal rack with suitable rubber mat.

6. Adequate number of fire buckets with stand and fire extinguishers to deal
with oil and electrical fire should be provided.

7. The selection of the generator sets shall be made in accordance with the
load sharing consideration for essential and non-essential loads of the
installation.

8. Also the applicable derating factors recommended by the manufacturer

should be given due consideration for arriving at capacity of the
generator.

9. An all round clearance of not less than 750 mm should be provided for
the generator. Also the door provided for acoustic enclosure of generator
should be openable without any hindrance.

10. Controls

The control panel should comprise adequate control and protection for
the generator with required meters, indication lamps and protective
relays.

i. For generator sets up to 100 kVA, switch fuse / fuse switch or

circuit breaker may be provided. When fuses are provided as
back up protection before the contactor, a linked switch should be
73
 provided before the said fuses for isolation and to facilitate safe
renewal of fuses.

ii. For generator sets of 100 kVA and above, Circuit breakers of
adequate rating should be provided. An earth fault relay to trip
the circuit breaker should be provided to protect against earth
fault or leakage with protection class neutral CT of adequate
ratio.

iii. All generators of 1000 kVA and above shall be protected against
faults within the generator winding using restricted earth fault
protection or differential protection or by both.

iv. A detachable solid link should be introduced in the neutral circuit

of the generator and the neutral earthing should be done at the
outgoing side of the link.

11. Changeover Board

More than one source of supply should be interlocked to avoid paralleling

by the following means:

i. Use double throw knife type change over switch for rating upto 63
Amps.

ii. For generator sets of more than 63 Amps rating, a pair of 4 pole
Fuse switches mechanically interlocked with castle type
interlocks having required number of keys and locks should be
used for each three phase feeders.

iii. The generators should never be run in parallel with Electricity

Supply Authorities’ grid unless specific consent is obtained from
such authorities.

12. Cables

i. Generally armoured cables should be used for connecting the

generator. If unarmoured cables are used, these should be
enclosed in earthed metallic casing.

74
 ii. Recommended Size of Cables for Generator Sets

Capacity of Size of the cable (PVC Aluminium armoured cable)

Alternator in kVA
110 1 Run of 3 ½ core 95 Sq mm
160 1 run of 3 ½ core 240 sq mm
200 1 run of 3 ½ core 300 sq mm
250 1 run of 3 ½ core 400 sq mm or 2 runs of 3 ½ core 185
sq mm
320 2 runs of 3 ½ core 185 sq mm XLPE
380 2 runs of 3 ½ core 300 sq mm XLPE
550 3 runs of 3 ½ core 300 sq mm XLPE
625 4 runs of 3½ core 300 sq.mm XLPE or 3 runs of 3½
core 400 sq.mm XLPE
750 Bus Bar Trunking
[

Note: Equivalent size of XLPE cable can also be provided

13. Parallel Operation of Generators

a. When generators are to be operated in parallel, suitable paralleling

arrangement with synchroscope, timers, Draw out type circuit
breaker, Reverse power relay, under frequency, voltage and
current relays, master and trip supervision relays should be
provided.

b. There should be provision for isolation of neutral earthing circuit of

each generator and this neutral isolator should be closed first while
starting and opened last while switching OFF. Such isolator in the
neutral earthing circuit should be of motorized MCCB or contactor
of adequate short circuit duty.

c. In the case of parallel operation of generator sets, the following

measures should be observed:

i. The neutral of the generator which starts first should be in

closed condition while the neutral of the other generators are
kept open.

ii. Suitable interlock should be provided in the neutral earthing

circuit so as to ensure that source neutral is always earthed but
at only one point.

75
 iii. The breaker of any generator cannot be closed unless one of
the neutrals of the generators in parallel operation is connected
to the system.

iv. The neutral of one of the functioning generators alone should

be in closed condition while any one or more remaining
generators are pulled out of operation.

TNS System

Mechanical Interlock to ensure that the source neutral is always earthed

but at one point only

d. The size of the earth flats of each generator operated in parallel

should be adequate to withstand the fault current of all the
generators.

e. The turbo alternators in co-generation plants require detailed

protection and special consideration since such alternators are
operated in parallel with supplier’s grid. Both supplier’s sanction
and Government permission are required for the tie-up.

76
77
 CHAPTER – 7

OVERHEAD LINES AND BUILDING CLEARANCES

1. The important factors to be considered in OH power distribution design is

to maintain adequate clearance between the conductor and
ground/building so as to prevent dangerous contact with line; to provide
reliable support for the conductor and to ensure safe functioning of the
conductor during abnormal electrical and mechanical stress.

2. The breaking strength of the overhead line conductors should be justified

to satisfy the electrical and mechanical stress during abnormal conditions
on the basis of factor of safety of supports, span length and ultimate tensile
strength of conductor, factor of safety of supports.

3. The factor of safety of the supports should be worked out for each
overhead line.

4. The following minimum factor of safety should be ensured for the supports:

Type of Support Factor of Safety

Metal supports 1.5
Mechanically processed concrete 2.0
supports
Hand-moulded concrete supports 2.5
Wooden supports 3.0

5. Overhead line conductors shall have a breaking strength of not less than
350 kg.

6. The base of over-head line supports should be concreted and coping done
above ground level.

7. Suitable bi-metallic clamps should be provided for connections with bare

copper or copper cable for taking supply from the over-head ACSR
Conductors.

8. Shackle insulators should be used at angle points of the over-head lines.

9. Over-head lines erected in consumer’s premises should be provided with

earthed cradle type guarding.

10. Earthed guarding should be provided at the crossing of tele-communication

lines and consumers’ over-head lines.

78
11. Guarding should be provided between the conductors at different Voltages
or same voltage of different sources taken on the same support with
adequate clearances between the lines and guarding.

12. The metal supports and metallic fittings at the over-head line should be
earthed efficiently.

13. In-order to avoid movement of vehicles beneath OH lines, suitable height

limiting structure should be provided maintaining adequate vertical
clearances according to voltage level of OH lines .

14. No rods, pipes or similar materials shall be taken below or in the vicinity of
any bare over head conductors or lines.

15. In cases where there is a change in the type of distribution i.e. from OH
line to under ground cable, surge protection device should be provided at
cable take OFF point.

16. Danger notices should be affixed permanently in a conspicuous position on

supports of over-head lines.

17. The over-head line supports receiving two sources of supply should be
provided with a special type of caution notice to this effect.

18. Anti-climbing device should be provided on the over-head line supports.

19. Each stay wire of the over-head line should be earthed unless shackle
insulator has been placed in it at a height of not less than 3.0 metres from
the ground.

20. The following safe clearances for OH lines should be observed from the
ground level during erection and maintenance:

Minimum clearances to be maintained above ground of the lowest bare

conductors (Regulation 58 of CEAR 2010)

Voltage not Voltage exceeding Voltage exceeding

Location exceeding 650 650 volts but not 650 volts but not
volts exceeding 33 kV exceeding 33 Kv
Across the 5.8 metres 6.1 metres 6.1 metres
street
Along the 5.5 metres 5.8 metres 6.1 metre
street
At places 4.6 metre 5.2 metre 5.2 m + 0.3 m for
other than every 33 kV or part
street there of

79
21. The following safe working clearances for OH lines should be observed
from the nearby buildings during erection and maintenance

Minimum clearances to be maintained for OH lines passing

above/adjacent to any building (Regulation 60 & 61 of CEAR 2010)

Type of OH lines Vertical clearance Horizontal clearance

Voltage not exceeding 2.5 metre 1.2 metre
650 volts
Voltage exceeding 3.7 metre 1.2 metre
650 volts up to and
including 11 kV
Voltage exceeding 3.7 metre 2.0 metre
11 kV and up to and
including 33 kV
Voltage exceeding 3.7 metre + 0.3 m 2.0 m + 0.3 m for
33 kV for every additional every additional 33
33 kV or part thereof kV or part thereof

80
 CHAPTER - 8

MULTI STOREYED BUILDINGS

(More than 15 metre in height)

1. Suitable isolating device with cut out or breaker to operate all phases
except neutral in the 3 Phase, 4 wire circuit should be fixed at the point of
commencement of supply, in a conspicuous position at a height of not
more than 1.7m above the ground so as to completely isolate the supply to
the building in case of emergency.

2. The type of Group control, primary control and secondary control for the
consumer’s transformer should be as per Table furnished under the
chapter “Substation’’.

3. Dry type of Transformers only should be used for the installations inside
the residential and commercial buildings.

4. The setback clearance permitted by the CMDA /DTCP/Local body should

be strictly observed for the building. Location of Transformers, Generators,
Water sewage plant, routing of the bus duct, exhaust pipe, cooling towers
or any other electrical equipments or switch gear should not infringe the
said setback clearance permitted by the building planning authorities.

5. The main panel room should be located at the periphery of the building in
the ground floor with direct access from outside and it should be well
ventilated .

6. Adequate clearance should be provided for the transformers, generators,

panels, switch boards and main panel as per Table furnished under the
relevant chapters.

7. TNS type earthing should be adopted for the MSB residential building
installations.

8. The cables for the floors should be taken in a separate duct.

9. The main power panels i.e. HT panel, main LT panel, main LT distribution
board and essential power panels and other such major panels should be
provided with linear heat sensing tubes with CO2 cylinder.

10. Doors of electrical panel rooms at each floor should be of atleast 2 hours
fire resistant.

11. The building should be protected against Lightning by installing lightning

arrestors in conformity with Part 1/section 15 of National Electrical Code,
2011 and IS 2309

81
12. The stand by generating set must be provided for all multi storeyed
buildings.

13. The following loads should be fed from the stand by generating set to
enable continuity of supply in the event of failure of mains:

a. Lighting in common areas, namely staircase, corridor, lift lobbies,

entrance hall, common toilets
b. Fire Lift
c. Fire Fighting pumps
d. Fire alarm control panel
e. Security lighting,
f. Water supply pump
g. Any other functional and critical loads.
h. Further, the above circuits should be fed from the main panel directly.

14. No other service pipes and cables should be taken along the ducts
provided for laying the power cables.

15. Electrical cables should not cross any other telephone cables.

16. All ducts provided for the power cables and other services should be
provided with fire barriers of four hours fire rating at each floor crossing.

17. The rising mains should be run in separate shafts or if run in the same
shaft each rising main should be separated from the other rising mains by
a baffle wall of atleast 2 hours fire resistant rating.

18. The power and lighting panel at each floor should preferably have alternate
feeder provision.

19. Two separate and distinct earth leads of adequate size should be provided
along the vertical trays.

20. Aviation lighting should be provided in the highest part of the building.

21. Permission under Tamil Nadu Lift Act and Rules, 1997 should be obtained
from the concerned Electrical Inspector for the lifts erected at the building

22. Fire lift of minimum capacity of 8 persons with necessary fire man's control
circuit should be provided.

23. Fire lift with necessary fireman's control circuit should be provided for the
building of height more than 24 m.

24. The MCBs controlling the staircase and corridor lighting should be located
in such a way that the switch is easily approachable for the fire fighting
staff.

82
25. Emergency lights fed from the UPS should be provided for the common
passageways, staircase and Emergency rooms.

26. Lighting circuit for lift cars should be availed from emergency lighting
distribution boards.

27. Fire fighting system such as sprinklers, Fire hydrant system, Smoke
detectors, Heat detectors, Fire alarm system etc. should be provided as
per National Building code, 2005.

28. An alarm system should be provided to give caution in the event of power
failure for the fire pumps.

29. The fire pumps should preferably be housed in a separate building located
at least 6 m away from all other building.

30. A direct feeder, without any tappings should be laid from the substation to
the pump house to ensure that the supply to the fire pumps is entirely
independent of all other electrical equipment in the premises viz, even
when power throughout the rest of the premises is switched off, supply to
the fire pumps remains available uninterrupted.

31. The fire pump circuit should be protected at its origin by a circuit breaker in
which either the no volt coil is removed or an automatic re-setting type of
no-volt coil is fitted and the overload setting should be so adjusted as to
permit the motor to carry an overload of 50 percent of its rated capacity.

32. Alternate source of supply and alternate feeding arrangement should be

provided for the Fire panel.

33. Cables for motors of fire pumps and their switchgear should be either
armoured or enclosed in heavy gauge screwed steel conduit

34. Fire pumps should be worked for at least 15 min each week and records of
the same should be maintained.

35. The starting switchgear for the fire pumps should be suitable direct on line
starting

36. The motor rating should be adequate to drive the pump when operating on
150 percent of rated flow.

37. Space heaters should also be provided for the MV motors where they are
located below ground level in order to maintain the motor winding in a dry
condition. Adequate drainage should also be provided in the pump house
in such cases.

83
38. Motors wound for high-tension supply should have suitable fixed warming
resistance to maintain the motor windings in a dry condition at all times and
particularly during the monsoon.

39. The motors should be wound for Class-E insulation and the windings
should be vacuum impregnated with heat and moisture-resisting varnish
preferably glass-fibre insulated, to withstand tropical conditions.

40. Wiring to the flats/apartments should be independent for each

flat/apartment and enclosed in separate metal conduits or done using
armoured cable.

41. Wiring within the flats should be of FRLS type.

42. In the cases of feeding single phase loads from three phase circuit, phase
segregated DB’s should provided in order to minimise propagation of fire.
Further, sufficient size of bus bars should be provided at both the phase
and neutral distinctly for the final outgoing circuit leads in such DBs.

43. The wiring arrangement taken in false flooring and false ceiling should be
laid through earthed metal conduit arrangement.

44. The rating of the MCB control at the final lighting circuit should not exceed
6A

45. The supply cable to each flat should be taken in separate metal conduits.

46. The following safety requirements as specified in item 14.2 of section 1 of

Part 3 of NEC 2011 should be followed.

a. All outlets for domestic electrical appliances should be of three-pin

socket type, where the third socket should be connected to the earth.

b. All the single pole switches should be on phase or live conductor only.

c. The electrical outlets for appliances in the bathrooms should be away

from the shower or sink.

d. The electrical outlets should not be located above the gas stove.

e. The clearance between the bottom most point of the ceiling fan and the
floor should be not be less than 2.4 metres.

f. Earth leakage circuit-breaker should be provided at the intake of power

supply at the consumer's premises.

84
47. Generator set sizing

a. Since standby source of supply is an essential component in MSBs,

proper sizing is to be proposed for catering the emergency and critical
loads like fire pump, fire lift, general lighting etc. for evacuation in an
emergency. In order to arrive at the required rating, the following
factors should be taken into consideration so as avoid any undersized
rating, defeating the very purpose of the standby source during
emergency.

b. Overload capability of generator sets is 1.5 times rated current for 30

seconds or 1.1 times rated current for one hour within a 12 hour period

c. Short circuit capability of generator sets is 3 to 4 times for 10 sec

d. Starting current capability of generator sets is 200% of full load current

of generator.

85
 CHAPTER - 9

LIGHTING

1. The lighting wiring should conform to IS 732 depending upon the

environmental conditions.

2. Lighting circuit and power circuit should not be mixed up or taken from the
same distribution board. Separate main lighting switch board fed from the
main panel should be installed for feeding all the lighting distribution boards
(LDBs).

3. However, if any building is far away from the main panel and availing of
supply from the main lighting board is not feasible, the lighting supply for
such building may be taken from the nearest sub switch board in such
building.

4. The lighting distribution Boards should not be located in close proximity to

water pipe lines/water taps etc.

5. No rewirable fuse DBs are permissible. The lighting supply should be

distributed to various section/hall/ departments/ offices etc. in the premises
through a standard seven segment/compartment type MCB distribution
boards or HRC fuse distribution boards.

6. The load on each phase of the LDBs should be balanced.

7. The LDBs, MCB controls, HRC fuse controls etc. should be mounted on
the earthed Metal work/non-inflammable material and should not be
mounted on wooden boards.

8. The earth wire should never be used as neutral. There must be a separate
neutral lead tapped from the neutral bus of the LDB for each final circuit.
There should be a separate earth lead for each final circuit.

9. Circuit of different phases should be taken in a separate conduit.

10. Different circuit of same phase should be taken in the same conduit
provided the number of wires drawn in the conduit is within the permissible
limit.

11. Where three phase and four wire circuit are taken for connecting alternate
lights, single conduit can be used provided the wires are of appropriate
voltage grading.

12. The incoming and outgoing supply leads of the LDBs should not be
enclosed in the same conduit.

86
13. The PVC conduits enclosing the supply leads should conform to relevant
standards.

14. The metal and PVC conduits should be suitably supported and clamped.

15. The ends of the metal conduit should be provided with PVC bushes to
avoid damage to the insulation of the wires.

16. Each single phase socket outlet should be of three pin type with the third
pin connected to earth and the single phase socket outlet should be
controlled by a switch installed adjacent thereto or combined therewith.

17. Where a number of high wattage lamps are required to be connected in a

circuit in places such as out-door yards, sports stadium, construction sites
etc, such circuits should be carefully designed with proper size of cable,
circuit protection and control by considering the type and nature of load
connected to it.

18. The rating of the MCB in the final lighting circuit should be 6A or lower
rated one as per the lighting load connected to the final circuit.

19. All the lighting circuits should be provided with 30mA sensitivity ELCB on
the incoming side of LDB’s.

20. The metallic street light poles should be earthed as per standards.

21. Adequate rating of control should be provided near each street light pole.

22. The light fitting erected outdoor should be of weather proof one.

23. The lighting wiring in the industries should be of earthed rigid metal conduit
wiring only.

24. Supply to the lights attached to the machine /inspection table should be
availed from the nearby LDB instead of from the power circuit of the
machine.

25. The light fittings in the hazardous area should be of flame proof one.

26. In the case of concealed conduit wiring within a wall or partition at a depth
of less than 50 mm from the surface, the said wiring should be restricted to
the following zones:

i. within 150 mm zone from the top of the wall or partition;

ii. within 150 mm zone of the angle formed by two adjoining wall or
partition;

87
27. When such concealed wiring requires connection to a point or accessory
on the wall or partition, the wiring outside the above said zones should be
made only in straight runs, either horizontally or vertically, to the point or
accessory.

28. The supply wires above the false ceiling and below the false flooring
should be taken through earthed metal conduits.

29. The controls of the lighting circuit in the godown should be erected outside
the godown.

30. The stair case and corridor lights should be on separate circuit and should
be independently connected so that it could be operated from the ground
floor accessible to fire fighting staff at any time.

88
 CHAPTER - 10

SAFE WORK PRACTICE

1 SHUT DOWN PROCEDURE

1.1 The safe procedures and practices to be adopted in electrical works

whether it involves a shut down, maintenance or repair of any electrical
installation/apparatus, definitely requires a thorough knowledge of
engineering, safety, repair techniques and the personnel should be
familiar with the particular features of the installation apparatus involved.

1.2 BASIC PRINCIPLES

a. Plan every job

b. Know the safety procedure that shall be followed
c. Use the correct tool for the job
d. Use procedures as tools
e. Isolate the equipment
f. Protect the person
g. Limit access to the work area to authorized personnel
h. Report to the person in charge in case of unsafe condition
i. Establish emergency safety procedure to deal with electrical
accidents

1.3 JOB BRIEFING

Brief the job to be done before the start of each job. The job briefing
include hazards associated with job, work instructions involved, special
procedures, energy source controls, personnel protective equipment
requirements.

1.4 WORK INSTRUCTIONS

Prepare the work instructions on the basis of thorough analysis of the job
and its hazards.

Electrical instructions may include but not be limited to

a. De- energizing circuits and means to prevent re-energisation

(lock out/ tagout)
b. Earthing conductors and all possible conducting parts
c. Controlling associated generating equipment

89
 d. Testing of equipment to ensure safe conditions
e. Provision of personnel protective equipment and tools
f. Qualified personnel
g. Details of the works to be performed

2 PERSONNEL PROTECTIVE EQUIPMENT & SAFE PROCEUDRE :

2.1 Qualified workers responsible for performing electrical work, repairs, or

trouble shooting electrical equipment shall wear or use personnel
protective equipment (PPE) and protective clothing that is appropriate for
safe performance of work.

a. Shoes
b. Helmets
c. Eye protectors
d. Body belts and safety straps
e. Work gloves
f. Rubber gloves tested at appropriate voltage levels and duly
inspected visually and tested before each use
g. Rubber sleeves and Barriers
h. Work clothes
i. Fire resistant clothing
j. Respirators
k. Earthing cables and Hardware
l. Tapes and Rulers
m. Metal fasteners
n. Double insulated tools
o. Work matrices

2.2 The typical job/safety work schedule matrix for adoption at MV/HV
Installations is given in the following tables:

90
Table - 1 Job/Safety Equipment Matrix - Use those applicable to the actual
job being performed on Medium Voltage Installations.

Insulated protective x x X x x X
Personal Protective

equipment such as gloves,

blankets and mats.
Safety Belt X
Equipment

Face Shield x X
Safety Glasses x x X x x X
Insulated Hand Tools x x X
Breaker Jacking Tools x
Tools

Insulated Fuse Puller X

Other Approved x X
Instrumentation
Test Equipment

Clamp Ammeter x
Approved Multi meter x X
Pulling Control Fuses or Power Fuses at

Jacking Breakers In/Out on Energized

Pulling/Inserting Plug-in devices on

Other Work- Energized Circuits

Voltage , Current Reading
Work Description

Energized MCCs
Probing

no load

MCCs

91
Table - 2 Job/Safety Equipment Matrix - Use those applicable to the actual
job being performed High Voltage Installations.

Fire Resistant Clothing X X X

Rubber Mat X X X
Personal Protective Equipment

Sleeves X X X X

High-Voltage Gloves X X X X

Tagout and Lockout X

Face Shield X

Safety Glasses X X X X

Hot Stick 5-ft Minimum X

Breaker Jacking Tools X

Other Approved X
Test Equipment

Instrumentation

High-Volt Detector X

Glow tester X
In/Out on Energized Equipment
Jacking Breakers
Work Description

Voltage Reading

Pulling Fuses–
De-energized
High potting

Equipment

No Load

92
 Table - 3 Job/Safety Equipment Matrix - Use those applicable to the actual
job being performed on overhead line/switchyard work

Fire R e s i s t a n t
x X x x x x x x
Clothing
Pole Inspection x
Confined Space
or Safe Work x x x x
Permit
Insulted or
x x x x x
Ground Surface
Sleeves x
H.V. Gloves /
x x x x x x
Personal Protective Equipment

Leather Protec.
Head Protection x x x x x x x x x x x x x x
Leather Gloves x
Face Shields x
Safety Glasses x x x x x x x x x x x x x x x x x x x x
Tagout and x x x
x x x x x x x
Lockout
Re-closure off x x
Live-Line Tools x
Reliable x x
x
Communications
Nonconductive x
x x x x
Rope
Hot Stick 3-ft x
x x
Minimum
Traveling Ground x x
High-Voltage x
Fuse Puller
Tree-Climbing
x
Equipment
Breaker Jacking
Tools

x
Tools
Other x
Instrumentation
as Approved by x x x x
Test Equipment

Electrical
Inspector
High-Volt.
x
Detector
Glow tester x x x x
Operate Disconnect Switch

String/Rem. Ground Cond.

Entering Trans./Brkr.

Interrupter Switch
Work Description

Dangerous Work

Tree Trimming
Climbing

93
SAFE PROCEDURE

1. De- energising

(i) De- energise all sources of electrical energy except where it is

necessary for troubleshooting, testing, or areas that are
infeasible to de- energise.
(ii) Discharge all energy sources such as capacitors and high
capacitance elements shall be short-circuited and earthed.
(iii) Live parts that operate at less than 50 volts to earth need not be
de-energised if there will be no increased exposure to electrical
burns

2. Verification of De-energised condition

(i) Verify that all live circuits, parts and other sources of electrical
energy have been disconnected, released or restrained
(ii) Operate the equipment operating controls, perform voltage
verification, inspect open switches and draw- out breakers etc to
assure the isolation of energy sources
(iii) Use the appropriate test equipment to test the circuit elements
and electrical parts of equipment. Proximity testers and solenoid
type devices should not be used to test for the absence of AC
voltage because they have a lower voltage below which they will
not detect voltage, even if it is present.

3 Equipment earthing

Earth all the De- energized lines and equipment

4 Personnel protective earth cable

(i) Personnel protective earth cable is required where residual

charges may accumulate.
(ii) Reduces the potential voltage differences at the work site to a
safe value in the event of accidental re-energisation.

5 Attaching and removing earths

(i) Inspect visually the earthing equipment before each use

(ii) Clean the surface to which the earth is to be attached before
installing the earthing clamp or use self –cleaning clamp.
(iii) Use hot-line tool for removing the earthing set
(iv) Remove the earthing cable conductors attached to earth bus
last.
94
6 Lock out procedure

(i) Required for mechanical service, breakdown and maintenance

operations if the procedures to be performed could involve
employee exposure to energized electrical parts to machinery
that could unexpectedly start up, or to a stored energy source on
the equipment or machinery.

(ii) Lock out devices: Padlocks, combination locks

(iii) TAG OUT

(a) Warning tag capable of being securely attached that

provides a warning not use the equipment. The tag
should be include reason for tag, name of person placing
the tag and how that person may be contacted and date
the tag was placed.

(b) Must be placed on the plug, conductors, disconnect

switch, fuse breakers or other positive means employed

7 Removing Lock and Tag

(i) Locks, tags must be left in place during all short absences such
as breaks or trips to pick up parts

(ii) When work is incomplete and temporarily suspended overnight

or over a weekend, all lock, tags and other safety warning
devices must be left in place.

(iii) When work is suspended for more than a weekend, the

equipment or machinery must be tagged as out of service,
permanently disconnected from all energy sources, and must
have its cover and access panels re-installed. All locks and other
tags must be removed.

8 RE-Energising

(i) Test and visual inspections

(ii) Warning employees
(iii) Removing lock and tag

95
PERMIT TO WORK SYSTEM

a. All work on major electrical installations shall be carried out under permit-
to-work system which is now well established, unless standing
instructions are issued by the competent authority to follow other
procedures.

b. In extenuating circumstances, such as for the purpose of saving life or

time in the event of an emergency, it may become necessary to start the
work without being able to obtain the necessary permit-to-work. In such
cases, the action taken shall be reported to the person-in-charge as soon
as possible.

c. The permit-to-work certificate from the person-in-charge of operation to

the person-in-charge of the men selected to carry out any particular work
ensures that the portion of the installation where the work is to be carried
out is rendered dead and safe for working.

d. All work shall be carried out under the personal supervision of a

competent person. If more than one department is working on the same
apparatus, a permit-to-work should be issued to the person-in-charge of
each department.

96
 Model form of permit-to-work
Name of the Organization........................................................................................

Department (issuing the permit).............................................................................

Permit No........................... Time................................ Date.........................

1. I..........................................................certify that the following apparatus has been

made dead, is isolated from all live conductors and has been connected to earth
and the work mentioned in para (3) can now be carried out in accordance with
the safety rules and regulations;

2. For the purpose of making the above apparatus dead, the following
switches/isolators/links/fuses have been opened and the section so isolated has
been earthed at each isolation point and danger notice plates fixed thereon:

Switches..................................................................
Isolators..................................................................
Links.......................................................................
Fuses......................................................................

3. Work to be carried out (testing work, if any, to be specifically mentioned)

.................................................................................................................................
........................................................................................................................

4. I have also recorded the above operations in the Log Sheet/Log Book including
the instructions for the person who may relieve me.

5. This permit is now being issued to.............................................................

(name of the person to whom the permit is being issued)for carrying out the work
mentioned in para (3).

(Signature of the permit issuing authority)

(Designation).............................
_____________________________________________________________________

Department (receiving the permit.............................................................

Permit No. ........................... Time........................... Date.........................

I................................................................................confirm that I have been issued this

permit by..................................... (name of the permit issuing officer) and have been
placed in direct and continuous charge of the work mentioned in para (3) and accept the
responsibility of carrying out the said work taking all necessary safety precautions to avoid
danger and no attempt will be made either by me or by men working under my control to
carry out any other work on any apparatus other than that detailed in paras (1) and (3) on
the reverse.

(Signature of the person receiving the permit and

responsible for carrying out the above work)

(Designation)..........................

97
I have transferred this permit to ..............................................................................

who will now be responsible for carrying out all the works mentioned in para (3)
on the reverse.........................................

(Signature of the person transferring the permit)

(Designation)
........................................
(Signature of the person receiving the permit)
(Designation)..............................

Time.......................................... Date............................

I confirm that the work specified in para (3) on reverse has been completed and
all workmen withdrawn and warned that it is no longer safe to work on the
apparatus mentioned in para (1) on the reverse. I also confirm that all temporary
earths and other connections made by me and by men under my control have
been removed except that any precautionary steps taken by the permit issuing
officer before the issue of this permit have not been interfered with by me or by
men under my control. I hereby return the permit for cancellation leaving the
dead apparatus ready for putting into service.

(Signature of the person returning the permit)

(Designation)...................
________________________________________________________________

Time.................. Date..................

The work mentioned in para (3) on the reverse has been carried out; all earths
made for the purpose have been removed and danger notice plates put aside.
The following switches/isolators/links/fuses have been closed and apparatus put
back into service. Entry has been made in the Log Sheet/Log Book.

Switches.........................................................................
Isolators.........................................................................
Links.........................................................................
Fuses.........................................................................

(Signature of the permit cancelling authority )

(Designation)..............

98
4. Intimation of accidents:

(1) If any accident occurs in connection with the generation, transmission,

supply or use of electricity in or in connection with, any part of the electric
lines or other works of any person and the accident results in or is likely
to have resulted in loss of human or animal life or in any injury to a
human being or an animal, such person or any authorized person of the
generating company or licensee, not below the rank of a Junior Engineer
or equivalent shall send to the Inspector a telegraphic report within 24
hours of the knowledge of the occurrence of the fatal accident and a
report in writing in Form A within 48 hours of the knowledge of
occurrence of fatal and all other accidents. Where possible a telephonic
message should also be given to the Inspector immediately, if the
accident comes to the knowledge of the authorized officer of the
generating company/licensee or other person concerned.

(2) For the intimation of the accident, telephone numbers, fax numbers and
addresses of Chief Electrical Inspector or Electrical Inspectors, District
Magistrate, police station, Fire Brigade and nearest hospital shall be
displayed at the conspicuous place in the generating station, sub-station,
enclosed sub-station/switching station and maintained in the Office of the
in-charge/owner of the Medium Voltage (MV)/High Voltage (HV)/Extra
High Voltage (EHV) installations.

(3) The following form has to be used in connection with reporting of an

electrical accident:

FORM FOR REPORTING ELECTRICAL ACCIDENTS - Form A

1. Date and time of accident.

2. Place of accident.

(Village/Town, Tehsil/Thana, District and State).

3. System and voltage of supply (Whether Extra High Voltage (EHV)/High

Voltage (HV)/Low Voltage (LV) Line, sub-station/generation
station/consumer’s installations/service lines/other installations).

4. Designation of the Officer-in-charge of the generating company/licensee

in whose jurisdiction the accident occurred.

5. Name of owner/user of energy in whose premises the accident occurred.

6. Details of victim(s):
(a) Human
Full
Sl. Father’s Sex of Approxim Fatal/
Name Postal
No Name victim ate age non-fatal
address
1 2 3 4 5 6 7
99
 (b) Animal

Sl. Description Number Name(s) of Address(es) of Fatal/

No. of animal(s) (s) owner(s) owner(s) Non-fatal
1 2 3 4 5 6

7. In case the victim(s) is/are employee(s) of supplier:-

(a) designation of such person(s);

(b) brief description of the job undertaken, if any;

(c) whether such person/persons was/were allowed to work on the job.

8. In case the victim(s) is/are employee(s) of a licensed contractor, -

(a) did the victim(s) possess any electric workmen’s permit(s),

supervisor’s certificate of competency?

If yes, give number and date of issue and the name of issuing authority;

(b) name and designation of the person who assigned the duties of the
victim(s).

9. In case of accident in the system of the generating company/licensee,

was the permit to work (PTW) taken?

10. (a) Describe fully the nature and extent of injuries, e.g. ,
fatal/disablement (permanent or temporary) of any portion of the
body or burns or other injuries.

(b) In case of fatal accident, was the post mortem performed?

11. Detailed causes leading to the accident.

(To be given in a separate sheet annexed to this form).

12. Action taken regarding first aid, medical attendance etc. immediately after
the occurrence of the accident (give details).

13. Whether the District Magistrate and Police Station concerned have been
informed of the accident (if so, give details).

14. Steps taken to preserve the evidence in connection with the accident to
extent possible.

15. Name and designation(s) of the person(s) assisting, supervising the

person(s) killed or injured.

100
16. What safety equipments were given to or used by the person(s) who met
with this accident (e.g. rubber gloves, rubber mats, safety belts and
ladders etc.)?

17. Whether isolating switches and other sectionalizing devices were

employed to deaden the sections for working on the same? Whether
working section was earthed at the site of work?

18. Whether the work on the live lines was undertaken by authorised
person(s)? If so, the name and the designation of such person(s) may be
given.

19. Whether artificial resuscitation treatment was given to the person(s) who
met with the electric accident? If yes, how long was it continued before its
abandonment?

20. Names and designations of persons present at, and witnessed, the
accident.

21. Any other information/remarks.

Signature

Place: Name

Time: Designation

Date: Address of the person reporting

101
 CHAPTER - 11
LIFT

1. The following points are to be followed in the installation of the lifts:

1.1 General

1. The ERECTION of any lift installation should be carried out by the

manufacture of lifts or by an ‘Electrical and mechanical Engineering
company’ approved by Inspector of Lifts.

2. a. The MAINTENANCE of any lift installation should be carried

out by the manufacture of lifts or by an ‘Electro mechanical
Engineering company’ approved by Inspector of Lifts.

b. The name and address of the lift maintenance agency along

with the Registration number, the validity of the maintenance
contract licence etc. should be displayed visibly in the lift
machine room.

3. No additions or alterations to the lift and its installation shall be

carried out without previous permission in writing of the inspector.

4. a. A copy of the lift licence issued should be displayed visibly in

the lift car.

b. If the holder of this licence ceases to have interest in the lift

installation of which the licence is granted, the licence shall be
deemed to be invalid and it shall be surrendered to the
Inspector and lift stopped from operations.

c. The licensee shall not use the lift which is not in a safe
condition and shall be solely responsible for the safe
maintenance of lift.

1.2 Technical Features (Electrical)

1. Supply to the lift car lighting should be availed from an exclusively

separate circuit independent from the power supply to the control
panel.

2. A plug socket outlet and light with switch should be provided in the
lift well near the terminal floor entrance at each floor.

3. Emergency alarm push button switch should be provided in the lift

car with alarm bell operated from an independent battery source.

4. Battery operated emergency light should be provided in the lift car.

102
 5. Control Panels should have built in voltage stabilizer or CVT’s and
surge protectors for preventing any damage to its components.
6. Suitable pit switch should be provided in the lift pit and it should be
accessible from the lowest landing. When the pit depth is more
than 2m, there should be two pit switches, one accessible from the
lowest landing and the other at the pit itself.
11.3 Technical Features (Mechanical)
1. Car preference switch should be made available in the lift car for
the Hospital Lifts.
2. Vision panels of 100 mm x 300 mm size should be provided for the
lift car and landing doors.
3. a. Lift operator or the authorized persons should be given training
by the manufacture of lifts in the release procedure of lifts by
hand winding.
b. All the details of operation regarding the release of lifts by hand
winding with a pictorial display issued by the lift manufacture
should be permanently displayed in the machine room.
4. Collapsible gates are not permitted for the lift car and landing
doors. It should be of imperforated gates or automatic doors only.
5. a. Permanent ladder should be provided in the lift well pit if the
depth of the pit is more than 1300 mm.
b. Permanent type step ladder with adequate width and hand rails
or stair case with hand rails should be provided for the Lift
machine rooms.
6. Suitable guard should be provided for the Governor in the machine
room.
7. Provision of over speed Governor should be ensured so that
protection in an emergency from the free fall of a lift is achieved by
stopping such over speeding lift during the free fall.
8. a. Electrical as well as mechanical interlock should be provided in
such a way that
i) the lift does not start if the doors are not closed.
ii) the closing of doors is prevented if the passenger
movement is sensed either towards or away from the car.
b. The sensing should be of contact type (Re-tractable safety
edges) or Non contact type (Light curtain).
c. Suitable indication in the lift control panel should be provided
to indicate any failure in any of the interlock contacts.
103
9. Door pressure limit switch should be provided so that the force
imposed by the closing doors is limited by this switch.

10. Floor level indicators should be provided inside the car as well as
in the landings so as to indicate the actual position of the lift in
building. Further, the direction arrow indication should be provided
to indicate the direction of travel of the lift.

11. Bypass load function is preferable, since this is a facility for by

passing registered landing calls by a car loaded more than 80% of
its rated capacity.

12. Over load function should be provided so that any overloading of

the lift car exceeding 110% of the rated capacity prevents start of
car. Also a buzzer and visual indication should be provided in the
car to caution such an overloading condition.

13. Fireman’s switch should be provided in the left car so that the car
is brought to the fire evacuation floor where the fire switch is
operated. Provision should be made to ignore all landing calls
during this situation. A buzzer and visual indication should be
provided in the car to caution such a condition.

14. Oil buffers should be provided for the lift car/counter Weight when
the rated speed of the car is more than 1.5 metres per second.

15. The car buffers shall not be in bent condition. For all oil buffers, a
device should be provided for determining the quantity of oil to be
provided.

16. Suitable counterweight guard screen should be provided up to a

height of two metres from the floor of the pit except where
compensation sheave is provided.

17. The condition of trailing cable and its termination should be intact
through proper mechanical means so as to avoid detachment from
terminations.

18. The car capacity should be permanently displayed at the lift car.

19. The gap between car sill and landing sill shall not exceed 30mm at
each landing.

20. The lift shall stop, during operation, when the car door is opened in
case of manual operated car door. In case of power operated
doors the car door shall not open when the door button lift is
pressed during the travel of the lift.

21. Log book should be maintained in an up to date condition.

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