EP/6.

6 BD/REL/KAIGA 3&4 / 018

ERECTION PROCEDURE FOR 6.6 KV BUS DUCT 1 of 7

1. SCOPE:

This procedure covers the guidelines for 6.6 KV Bus Duct receipt, handling and
installation for all applicable areas of KAIGA 3&4 electrical package.

2. PURPOSE:

The purpose of this procedure is to provide guidelines for receipt, handling and
installation of 6.6 KV Bus Duct in all areas of plant. The Detailed commissioning
procedure shall be separately prepared.

3. APPLICABILITY:

This procedure is applicable for all the 6.6 KV Bus Duct used at KAIGA 3&4 .

4. REFERENCE DOCUMENTS:

1) Module specifications PP-E-1765 ( E-5 ).

2) Applicable codes and specifications .
2) Equipment layout drawings .
3) Manufacturers drawings .
4) Manufacturers instruction for erection & Pre commissioning activities .

5. RESPONSIBILITY:

Responsibility of implementation of this procedure lies with REL Site In Charge.

6. PREREQUISITES:

a) Shipping Release note along with Material receipt intimation cum acceptance report.
b) Availability of required storage area shall be ascertained.
c) The Energized Power Distribution Board shall be available at site.
d) Approved drawings shall be available for erection of 6.6KV Bus Duct .
e) Ensure area clearance for equipment erection .
f) The civil embedded plates for bus duct shall be checked with respect to approved GA
drawings .
g) Required no. of 6.6KV Bus Duct with all its accessories shall be available at site .
h) Route and feasibility of bus duct shifting and lifting shall be surveyed thoroughly .
i) Ensure that lockable door is provided before Energisation .

Prepared By : Concurred By : Approved By :

CH.V.V.S.Nagababu TASN Murthy J.P.Athalye
 EP/6.6 BD/REL/KAIGA 3&4 / 018

ERECTION PROCEDURE FOR 6.6 KV BUS DUCT 2 of 7

j) Good Ventilation and illumination shall be available during the time of erection and
other activities .
k) Fire fighting system shall be effective & adequate.
l) Competent manpower for erection shall be employed
m) Approved procedure for welding and structural steel fabrication & erection shall be
followed .
n) Welding consumables shall be of approved make .
o) Calibrated instruments and testing equipments shall be made available .
p) Use of tested lifting/handling tools and tackles shall be ensured .
q) Ensure that lockable door is provided before Energization .

7.0 EQUIPMENT & ACCESSORIES:

a) Rolling pipes / Skid Rollers/ Crow bars .

b) Electrician tools .
c) Spanner sets .
d) Welding machine & all accessories .
e) Slings and ropes as per requirement .
f) 500V, 2500 V Meggars.
g) Torque wrench .
h) Crane and vehicle for equipment shifting.
8. PROCEDURE

8.1 RECEIPT OF BUS DUCT & ACCESSORIES :

a) Bus Duct and accessories received shall be checked with respect to packing list, BOM,
shipping release & test certificates.
b) Any damages observed in the consignment shall be brought to the notice of transporter
and supplier for immediate replacement .
c) Minor damages if observed shall be repaired / replaced with the approval of
Manufacturer and Engineer In Charge.
8.2 SHIFTING OF MATERIALS FROM STORAGE YARD TO ERECTION SPOT
a) Load the Bus Duct in vehicle from storage yard using a mobile crane/fork lift / Chain
pulley block .
b) Ensure correct Bus Duct is received from the stores and it is being taken to its
designated location / Position.

Prepared By : Concurred By : Approved By :

CH.V.V.S.Nagababu TASN Murthy J.P.Athalye
 EP/6.6 BD/REL/KAIGA 3&4 / 018

ERECTION PROCEDURE FOR 6.6 KV BUS DUCT 3 of 7

c) After loading the Bus Duct on the truck, tie them to sides of truck firmly by rope.
d) Verify the route from unloading spot to erection spot for free access
e) After reaching the nearest spot suitable to erection unload the Bus Duct .
f) For Bus Duct to be installed at higher elevations shift them from unloading bay to higher
elevation by using a EOT crane/ chain pulley blocks, through the openings planned in
the building for the purpose .
g) Shift the Bus Duct by putting skid rollers / Rolling Pipes under the bottom wooden pallet
& pushing the Bus Duct manually up to the erection spot. Ensure that the Bus Ducts are
pushed safely . Also ensure the safety of working personnel is as per the approved
safety procedures .
8.3 BUS DUCT ERECTION
Before starting the erection work, check that the center line of the complete bus duct
shall be inline with the center line of the equipments at both end . In case of any
substantial deviation, which may effect the erection of bus duct installation, the same
should be referred to Purchaser engineers. The remedial measures should be planned in
advance which may consist of leveling by suitable packings, chipping of the concrete
floor or wall etc. or rectification of the components with the concurrence of Engineer In
Charge .
8.3.1 Sequence of erection: The following Sequence will be followed.
Erection of steel work.
Initially Temporary supports like "H " Frame or temporary steel supports hanged from top
will be provided for lifting of enclosures with Busbars . Permanent supports will be made
( Welded with the EP"S ) only when rough alignment of Bus Duct is completed and
before joining of enclosures / Bus bars .
Site welding of Hot dip galvanized structures shall be carefully done at site . All welded
surface shall be immediately sprayed with Zinc spray after removing the weld slag .
Next place all longitudinal & cross channels in positions. Adjust all levels & bolt/weld
them. Check up the correctness of the levels & positions of various installed structures
Indoor portion of the bus duct shall be supported from the ceiling beams or side walls as
per approved drawings . For outdoor portions of bus duct, foundation shall be made for
supporting structure as per approved drawings & procedure. Support structures shall be
erected as per relevant approved drawings .

Prepared By : Concurred By : Approved By :

CH.V.V.S.Nagababu TASN Murthy J.P.Athalye
 EP/6.6 BD/REL/KAIGA 3&4 / 018

ERECTION PROCEDURE FOR 6.6 KV BUS DUCT 4 of 7

8.3.2 Erection of enclosure along with its bus bars

Before the installation of enclosures in position, each assembly of enclosure and
conductors complete with insulation support will be checked for correctness and
cleanliness. The various enclosure assemblies will be erected as per layout drawing.
Bolt up the flanges of adjacent sections of busduct. Ensure gaskets are provided in
between the flanges. Tighten the flanges to the torque level as recommended by the
manufacturer in the following table. Size of the bolts, number of bolts and accessories
shall be as per drawing.
Sl.No Size of bolt Torque level for Gasketed joint( Kg-cm ) Torque level at Bus
bar joints ( kg-cm )
1 M10 120 +/- 25 200 +/- 40
2 M12 300 +/- 60 450 +/- 100

For outdoor portions of bus duct, foundation shall be made for supporting structure as
per approved drawings & procedure. Support structures shall be erected as per relevant
approved drawings. Prior to this, check the tightness of all support insulators and megger
each section of Bus Duct before taking up the erection. The Busduct enclosure is having
the canopy shaped top for the entire Busduct (including indoor and outdoor)
8.3.3 Erection of Bus bar joints.
Bus bar joints will be bolted as specified for the installation as follows.
a. Check the contact surface
- Surface will be flat and even.
- Remove any irregularities if any (Slight hammering using wood)
b. Preparation of Contact
- Remove temporary protective covering provided.
- Clean the surface with soft cloth to remove dust.
- Apply a thin and even coating of contact grease.
c. Mounting instructions
- Bring the pieces to be assembled to contact, then place bolts, flats washers.
- Gradually tighten the bolts screws or nuts and finally apply tightening torque using
torque wrench.
- Torque values shall be as per Manufacturers recommendation as shown in clause 8.3.2

8.3.4 Erection of Flexible Connections

Prepared By : Concurred By : Approved By :

CH.V.V.S.Nagababu TASN Murthy J.P.Athalye
 EP/6.6 BD/REL/KAIGA 3&4 / 018

ERECTION PROCEDURE FOR 6.6 KV BUS DUCT 5 of 7

Silver coated flexible are provided for busduct joints and between the bus duct and the
equipment.
8.3.5 Erection of Flexible Expansion Joints and Wall frame assembly.
Erection of wall frame assembly shall be done as follows:
Check the wall opening dimensions and the wall frame assembly. The wall opening shall
be bigger than the wall frame. If EPs are not available then weld the anchoring angles
(Spitted Edges of the angle) to the wall frame and grout the wall frame. While grouting,
ensure the level and the measurements of the wall frame as per drawing
Flexible expansion joints shall be installed at locations as given in the GA drawing .
Tightening of Bolts shall be as per Manufacturers recommendation as shown in clause
8.3.2 . Install seal off bushing in wall frame assembly as per the drawing .
8.3.6 Erection of Rubber Bellows Assembly
Bellows are made of EPDM rubber and the purpose is to achieve a flexible airtight and
insulating junction. The bellow is designed for flanged connections , shall be installed at
the termination of the bus ducts at transformer end box and switchgear cubicle .
Mounting procedure will be as given below:
1. Preliminary check - Check main dimension.
- Confirm no damage (Cracks, tears etc)
2. Preparation - Carefully clean the resting surface.
- Remove all the traces of grease, dust etc.
- Remove all the irregularities if any by grinding.
- Fit the bellows on one of its supports, taking care not to scratch.
3. Final fitting - To be done only after bolted connections are done
after checking and confirming nothing is kept inside.
- Fit the bellows on its 2nd support.
- Tighten all bolts as per Manufacturers Recommendation.
8.3.7 Space Heater Wiring :
Cleats are provided to the enclosure for space heater cable dressing. Cabling for anti-
condensation space heaters mounted in the busduct as per the approved scheme. Before
closing of Inspection covers, ensure that space heaters and the thermostat are temporarily
checked for its operation.

Prepared By : Concurred By : Approved By :

CH.V.V.S.Nagababu TASN Murthy J.P.Athalye
 EP/6.6 BD/REL/KAIGA 3&4 / 018

ERECTION PROCEDURE FOR 6.6 KV BUS DUCT 6 of 7

8.3.8 Erection of Silica Gel Breather and Drain valves :

Fixing of Silica Gel Breather and Filter type drain valves shall be done as per Drawing .
Before lifting for erection , check for physical condition of silica gel and take corrective
action if required .
8.3.9 Cleaning of Bus Duct and closing of Covers
Before putting the Inspection covers all the insulators will be cleaned again and will be
checked for any damage . The Bus Duct will also be cleaned and dried up for any
moisture / condensate . Thoroughly check the interior of every enclosure and ensure
that these are free from any foreign Matter.
8.3.10 Earthing of Bus Duct
Install the earthing strip along the busduct; clamp the strip on the busduct externally on
the clamps provided on the bus duct enclosure. Earthing of busduct to be completed
as per earthing drawings. Earth all the busduct supporting structures from the earth
strip running on the busduct as per the relevant approved drawing .
8.3.11 Procedure for Conducting Various Preliminary Checks on 6.6 KV Bus Duct
1) Check the name plate details as per the specifications
2) Check for any physical damage
3) Check for tightness of all bolts/clamps and connection terminals as per clause 8.3.2
4) Check for cleanliness of busduct and its support Insulators..
5) Check the continuity of busbars from terminal equipment on one side to that on the
other side.
6) Check the continuity of seal off bushing insulators.
7) Check for earthing of busducts as per drawing.
8) Check for insulation resistance of busduct.
9) Check the clearance between the line bus with respective to enclosures at such
places where even the bus bars will have 90 deg. bends.
9.0 ACCEPTANCE CRITERIA:
Conformity to schedule, drawings & specifications and manufacturers instructions.
10. CHECK LIST
a) The following checks has to be done as per the erection procedure. Remaining
checks for Pre Commissioning will be covered in Commissioning procedure.

Sl.No Procedure number Description

1. CH/REL/6.6 KV Bus Duct Installation of 6.6KV Bus Duct

Prepared By : Concurred By : Approved By :

CH.V.V.S.Nagababu TASN Murthy J.P.Athalye
 EP/6.6 BD/REL/KAIGA 3&4 / 018

ERECTION PROCEDURE FOR 6.6 KV BUS DUCT 7 of 7

2. CH/BSES/6.6 KV Bus Duct Insulation resistance on busbars for 6.6 KV Bus Duct
3. CH/BSES/6.6 KV Bus Duct Clearance between bus bars for 6.6 KV Bus Duct.

11. PRECAUTION:
11 a) Check the physical conditions of 6.6 KV Bus Duct before shifting from stores.
b) Competent workmen shall be used for shifting and erection of 6.6 KV Bus Duct .
c) While transporting in the vehicle 6.6 KV Bus Duct shall be tightened and wooden
packings shall be provided .
d) Proper ropes shall be used for shifting the 6.6 KV Bus Duct .
e) Discharge the bus after conducting IR test with discharging rod connected to the
earth
f) Ensure safety of operating and testing personnel while conducting IR test.
Barricade the area to avoid movement of personnel at the time of carrying tests .
g) Do not store Bus Duct in open and humid areas.
h) Do not send Bus Ducts to erection spot with out inspection of transport damage .
i) Do not leave doors / blank cut out if any in open condition .
12. RECORDS
Manufacturers test reports for 6.6 KV Bus Duct shall be available .
Erection checklist No. CH/REL/6.6 KV Bus Duct 84 to 86 for 6.6KV Bus Duct.
Calibration certificate of testing instruments shall be available .

13. DISTRIBUTION

Will be distributed to
NPCIL Quality Control Dept
NPCIL Execution Dept
NPCIL Planning Dept.
NPCIL Field Engg.Dept.

Total No. Of copies to be distributed is 4 Nos.

Prepared By : Concurred By : Approved By :

CH.V.V.S.Nagababu TASN Murthy J.P.Athalye